Advanced voxel-based CAD modelling for FSI simulations for automotive structures design

Additive Manufacturing (AM) is nowadays considered an important alternative to traditional manufacturing processes. AM technology shows several advantages in literature as design flexibility, and its use increases in automotive, aerospace and biomedical applications. As a systematic literature review suggests, AM is sometimes coupled with voxelization, mainly for representation and simulation purposes. Voxelization can be defined as a volumetric representation technique based on the model’s discretization with hexahedral elements, as occurs with pixels in the 2D image. Voxels are used to simplify geometric representation, store intricated details of the interior and speed-up geometric and algebraic manipulation. Compared to boundary representation used in common CAD software, voxel’s inherent advantages are magnified in specific applications such as lattice or topologically structures for visualization or simulation purposes. Those structures can only be manufactured with AM employment due to their complex topology. After an accurate review of the existent literature, this project aims to exploit the potential of the voxelization algorithm to develop optimized Design for Additive Manufacturing (DfAM) tools. The final aim is to manipulate and support mechanical simulations of lightweight and optimized structures that should be ready to be manufactured with AM with particular attention to automotive applications. A voxel-based methodology is developed for efficient structural simulation of lattice structures. Moreover, thanks to an optimized smoothing algorithm specific for voxel-based geometries, a topological optimized and voxelized structure can be transformed into a surface triangulated mesh file ready for the AM process. Moreover, a modified panel code is developed for simple CFD simulations using the voxels as a discretization unit to understand the fluid-dynamics performances of industrial components for preliminary aerodynamic performance evaluation. The developed design tools and methodologies perfectly fit the automotive industry’s needs to accelerate and increase the efficiency of the design workflow from the conceptual idea to the final product.

Liquid biofuels for aviation: valorisation of the by-product biochar

Biochar is a carbonaceous material produced through pyrolysis of biomass. One promising application of biochar is phosphorus recovery from wastewater. Phosphorus is a vital nutrient for plant growth, but its use in fertilizers often leads to runoff or leaching. Wastewater treatment plants discharge large amounts of phosphorus-rich wastewater, contributing to eutrophication and ecological harm. Biochar can sorb phosphorus, retaining it in solid form. In this thesis, two composites made of biomass and dolomite or shells exhibited superior phosphate sorption compared to biochar alone, reaching up to 100% sorption. Biochar also finds use in soil remediation, specifically in cleaning up contaminated soil. Polycyclic aromatic hydrocarbons (PAHs), which can be carcinogenic and toxic, can be present in soil. Biochar adsorb PAHs, preventing their leakage or bioaccumulation. Hetero-PAHs, a subclass of PAHs with nitrogen, sulfur, or oxygen atoms in their ring structures, are particularly challenging to degrade. Little is known about their behavior or sorption onto biochar. In this thesis, biochar and activated carbon were effective in immobilizing PAHs and hetero-PAHs in real soils, with rates of immobilization reaching 100%. Biochar performed equally or better than activated carbon, offering a cost-effective alternative due to its lower price. Biochar reduce of metal(loid)s mobility in soil. Metal(loid)s like lead, zinc, and arsenic can contaminate soil through industrial sources, agricultural runoff, and other pollution, and are toxic to plants and animals, rendering the soil unsuitable for agriculture. When biochar is added to contaminated soil, it binds to metal(loid)s, preventing leaching into the environment. A biomass-dolomite composite was compared to activated carbon for immobilizing metal(loid)s in contaminated soils. The composite generally outperformed activated carbon and exhibited the ability to immobilize arsenic. In summary, biochar shows promise for phosphorus recovery, soil remediation, and reducing the mobility of heavy metals, offering cost-effective and sustainable solutions to these environmental challenges.