Study and experimental characterization of the laser welding process for the manufacturing of electric powertrain components in the automotive industry

The PhD project that will be presented in this thesis is focused on the study and optimization of the production process for the manufacturing of electrical powertrain components in the automotive field using the laser beam welding process (LBW). The objective is to define, through experimental activities, an optimized process condition for applications in the electrical field that can be generalized, that is, which guarantees its reproducibility as the types of connections vary and which represents the basis for extending the method to future applications in e-mobility sector. The work developed along two lines of research, the convergence of which made it possible to create prototypes of battery modules based on different types of lithium-ion cells and stator windings for electric motors. On the one hand, the different welding configurations involving the production of batteries based on pouch cells and therefore the welding of aluminum and copper in dissimilar configuration were studied, while for the prismatic cells only one configuration was analyzed. On the other hand, the welding of pure copper hairpins with rectangular shape in edge joint configuration was studied for the production of stator windings. The experimental tests carried out have demonstrated the feasibility of using the LBW process for the production of electric powertrain components entirely designed and developed internally as the types of materials and welding configurations vary; the methodologies required for the characterization methods, necessary for the end-of-line tests, for the evaluation of the properties of the different joint configurations and components (battery and electric motor) were also defined with the aim of obtaining the best performance. The entire doctorate program was conducted in collaboration with Ferrari Auto S.p.A. and the direct industrial application of the issues addressed has been faced.

Shallow and deep deformation in northern Apennines region using seismological data

For its particular position and the complex geological history, the Northern Apennines has been considered as a natural laboratory to apply several kinds of investigations. By the way, it is complicated to joint all the knowledge about the Northern Apennines in a unique picture that explains the structural and geological emplacement that produced it. The main goal of this thesis is to put together all information on the deformation - in the crust and at depth - of this region and to describe a geodynamical model that takes account of it. To do so, we have analyzed the pattern of deformation in the crust and in the mantle. In both cases the deformation has been studied using always information recovered from earthquakes, although using different techniques. In particular the shallower deformation has been studied using seismic moment tensors information. For our purpose we used the methods described in Arvidsson and Ekstrom (1998) that allowing the use in the inversion of surface waves [and not only of the body waves as the Centroid Moment Tensor (Dziewonski et al., 1981) one] allow to determine seismic source parameters for earthquakes with magnitude as small as 4.0. We applied this tool in the Northern Apennines and through this activity we have built up the Italian CMT dataset (Pondrelli et al., 2006) and the pattern of seismic deformation using the Kostrov (1974) method on a regular grid of 0.25 degree cells. We obtained a map of lateral variations of the pattern of seismic deformation on different layers of depth, taking into account the fact that shallow earthquakes (within 15 km of depth) in the region occur everywhere while most of events with a deeper hypocenter (15-40 km) occur only in the outer part of the belt, on the Adriatic side. For the analysis of the deep deformation, i.e. that occurred in the mantle, we used the anisotropy information characterizing the structure below the Northern Apennines. The anisotropy is an earth properties that in the crust is due to the presence of aligned fluid filled cracks or alternating isotropic layers with different elastic properties while in the mantle the most important cause of seismic anisotropy is the lattice preferred orientation (LPO) of the mantle minerals as the olivine. This last is a highly anisotropic mineral and tends to align its fast crystallographic axes (a-axis) parallel to the astenospheric flow as a response to finite strain induced by geodynamic processes. The seismic anisotropy pattern of a region is measured utilizing the shear wave splitting phenomenon (that is the seismological analogue to optical birefringence). Here, to do so, we apply on teleseismic earthquakes recorded on stations located in the study region, the Sileny and Plomerova (1996) approach. The results are analyzed on the basis of their lateral and vertical variations to better define the earth structure beneath Northern Apennines. We find different anisotropic domains, a Tuscany and an Adria one, with a pattern of seismic anisotropy which laterally varies in a similar way respect to the seismic deformation. Moreover, beneath the Adriatic region the distribution of the splitting parameters is so complex to request an appropriate analysis. Therefore we applied on our data the code of Menke and Levin (2003) which allows to look for different models of structures with multilayer anisotropy. We obtained that the structure beneath the Po Plain is probably even more complicated than expected. On the basis of the results obtained for this thesis, added with those from previous works, we suggest that slab roll-back, which created the Apennines and opened the Tyrrhenian Sea, evolved in the north boundary of Northern Apennines in a different way from its southern part. In particular, the trench retreat developed primarily south of our study region, with an eastward roll-back. In the northern portion of the orogen, after a first stage during which the retreat was perpendicular to the trench, it became oblique with respect to the structure.

Meccanismi di formazione dei tubi di lava

Two analytical models are proposed to describe two different mechanisms of lava tubes formation. A first model is introduced to describe the development of a solid crust in the central region of the channel, and the formation of a tube when crust widens until it reaches the leve\'es. The Newtonian assumption is considered and the steady state Navier- Stokes equation in a rectangular conduit is solved. A constant heat flux density assigned at the upper flow surface resumes the combined effects of two thermal processes: radiation and convection into the atmosphere. Advective terms are also included, by the introduction of velocity into the expression of temperature. Velocity is calculated as an average value over the channel width, so that lateral variations of temperature are neglected. As long as the upper flow surface cools, a solid layer develops, described as a plastic body, having a resistance to shear deformation. If the applied shear stress exceeds this resistance, crust breaks, otherwise, solid fragments present at the flow surface can weld together forming a continuous roof, as it happens in the sidewall flow regions. Variations of channel width, ground slope and effusion rate are analyzed, as parameters that strongly affect the shear stress values. Crust growing is favored when the channel widens, and tube formation is possible when the ground slope or the effusion rate reduce. A comparison of results is successfully made with data obtained from the analysis of pictures of actual flows. The second model describes the formation of a stable, well defined crust along both channel sides, their growing towards the center and their welding to form the tube roof. The fluid motion is described as in the model above. Thermal budget takes into account conduction into the atmosphere, and advection is included considering the velocity depending both on depth and channel width. The solidified crust has a non uniform thickness along the channel width. Stresses acting on the crust are calculated using the equations of the elastic thin plate, pinned at its ends. The model allows to calculate the distance where crust thickness is able to resist the drag of the underlying fluid and to sustain its weight by itself, and the level of the fluid can lower below the tube roof. Viscosity and thermal conductivity have been experimentally investigated through the use of a rotational viscosimeter. Analyzing samples coming from Mount Etna (2002) the following results have been obtained: the fluid is Newtonian and the thermal conductivity is constant in a range of temperature above the liquidus. For lower temperature, the fluid becomes non homogeneous, and the used experimental techniques are not able to detect any properties, because measurements are not reproducible.

InSAR deformation measurements of the earthquake cycle in transcurrent tectonic domains, analytical and analog modeling

I applied the SBAS-DInSAR method to the Mattinata Fault (MF) (Southern Italy) and to the Doruneh Fault System (DFS) (Central Iran). In the first case, I observed limited internal deformation and determined the right lateral kinematic pattern with a compressional pattern in the northern sector of the fault. Using the Okada model I inverted the observed velocities defining a right lateral strike slip solution for the MF. Even if it fits the data within the uncertainties, the modeled slip rate of 13-15 mm yr-1 seems too high with respect to the geological record. Concerning the Western termination of DFS, SAR data confirms the main left lateral transcurrent kinematics of this fault segment, but reveal a compressional component. My analytical model fits successfully the observed data and quantifies the slip in ~4 mm yr-1 and ~2.5 mm yr-1 of pure horizontal and vertical displacement respectively. The horizontal velocity is compatible with geological record. I applied classic SAR interferometry to the October–December 2008 Balochistan (Central Pakistan) seismic swarm; I discerned the different contributions of the three Mw > 5.7 earthquakes determining fault positions, lengths, widths, depths and slip distributions, constraining the other source parameters using different Global CMT solutions. A well constrained solution has been obtained for the 09/12/2008 aftershock, whereas I tested two possible fault solutions for the 28-29/10/08 mainshocks. It is not possible to favor one of the solutions without independent constraints derived from geological data. Finally I approached the study of the earthquake-cycle in transcurrent tectonic domains using analog modeling, with alimentary gelatins like crust analog material. I successfully joined the study of finite deformation with the earthquake cycle study and sudden dislocation. A lot of seismic cycles were reproduced in which a characteristic earthquake is recognizable in terms of displacement, coseismic velocity and recurrence time.

Giunzione mediante laser di materiali difficili, ibridi ed a struttura cellulare

Lo studio presentato in questa sede concerne applicazioni di saldatura LASER caratterizzate da aspetti di non-convenzionalità ed è costituito da tre filoni principali. Nel primo ambito di intervento è stata valutata la possibilità di effettuare saldature per fusione, con LASER ad emissione continua, su pannelli Aluminum Foam Sandwich e su tubi riempiti in schiuma di alluminio. Lo studio ha messo in evidenza numerose linee operative riguardanti le problematiche relative alla saldatura delle pelli esterne dei componenti ed ha dimostrato la fattibilità relativa ad un approccio di giunzione LASER integrato (saldatura seguita da un post trattamento termico) per la realizzazione della giunzione completa di particolari tubolari riempiti in schiuma con ripristino della struttura cellulare all’interfaccia di giunzione. Il secondo ambito di intervento è caratterizzato dall’applicazione di una sorgente LASER di bassissima potenza, operante in regime ad impulsi corti, nella saldatura di acciaio ad elevato contenuto di carbonio. Lo studio ha messo in evidenza come questo tipo di sorgente, solitamente applicata per lavorazioni di ablazione e marcatura, possa essere applicata anche alla saldatura di spessori sub-millimetrici. In questa fase è stato messo in evidenza il ruolo dei parametri di lavoro sulla conformazione del giunto ed è stata definita l’area di fattibilità del processo. Lo studio è stato completato investigando la possibilità di applicare un trattamento LASER dopo saldatura per addolcire le eventuali zone indurite. In merito all’ultimo ambito di intervento l’attività di studio si è focalizzata sull’utilizzo di sorgenti ad elevata densità di potenza (60 MW/cm^2) nella saldatura a profonda penetrazione di acciai da costruzione. L’attività sperimentale e di analisi dei risultati è stata condotta mediante tecniche di Design of Experiment per la valutazione del ruolo preciso di tutti i parametri di processo e numerose considerazioni relative alla formazione di cricche a caldo sono state suggerite.

Modelling, diagnostics and experimental analysis of plasma assisted processes for material treatment

This work presents results from experimental investigations of several different atmospheric pressure plasmas applications, such as Metal Inert Gas (MIG) welding and Plasma Arc Cutting (PAC) and Welding (PAW) sources, as well as Inductively Coupled Plasma (ICP) torches. The main diagnostic tool that has been used is High Speed Imaging (HSI), often assisted by Schlieren imaging to analyse non-visible phenomena. Furthermore, starting from thermo-fluid-dynamic models developed by the University of Bologna group, such plasma processes have been studied also with new advanced models, focusing for instance on the interaction between a melting metal wire and a plasma, or considering non-equilibrium phenomena for diagnostics of plasma arcs. Additionally, the experimental diagnostic tools that have been developed for industrial thermal plasmas have been used also for the characterization of innovative low temperature atmospheric pressure non equilibrium plasmas, such as dielectric barrier discharges (DBD) and Plasma Jets. These sources are controlled by few kV voltage pulses with pulse rise time of few nanoseconds to avoid the formation of a plasma arc, with interesting applications in surface functionalization of thermosensitive materials. In order to investigate also bio-medical applications of thermal plasma, a self-developed quenching device has been connected to an ICP torch. Such device has allowed inactivation of several kinds of bacteria spread on petri dishes, by keeping the substrate temperature lower than 40 degrees, which is a strict requirement in order to allow the treatment of living tissues.