Development of a novel heat treatment for high performances L-PBF Ti6Al4V alloy: microstructural and mechanical characterization

This work presents the experimental development of a novel heat treatment for a high performance Laser Powder Bed Fusion Ti6Al4V alloy. Additive manufacturing production processes for titanium alloys are particularly of interest in cutting-edge engineering fields, however, high frequency laser induced thermal cycles generate a brittle as built microstructure. For this reason, heat treatments compliant with near net shape components are needed before their homologation and usage. The experimental campaign focused on the development of a multi-step heat treatment leading to a bilamellar microstructure. In fact, according to literature, such a microstructure should be promising in terms of mechanical properties both under static and cyclic loads. The heat treatment development has asked for the preliminary analyses of samples annealed and aged in laboratory, implementing several cycles, differing for what concerns temperatures, times and cooling rates. Such a characterization has been carried out through optical and electron microscopy analyses, image analyses, hardness and tensile tests. As a result, the most suitable thermal cycle has been selected and performed using industrial equipment on mini bending fatigue samples with different surface conditions. The same tests have been performed on a batch of traditionally treated samples, to provide with a comparison. This master thesis activity has finally led to the definition of a heat treatment resulting into a bilamellar microstructure, promising in terms of fatigue performances with respect to the traditionally treated alloy ones. The industrial implementation of such a heat treatment will require further improvements, particularly for what concerns the post annealing water quench, in order to prevent any surface alteration potentially responsible for the fatigue performances drop. Further development of the research may also include push-pull fatigue tests, crack grow propagation and residual stresses analyses.

Heat-transfer enhancement with pulsed jets in turbulent pipe flow at high-Reynolds number

Improving heat transfer is a critical area of ​​research in various fields such as thermal engineering, energy conversion and aeronautical engineering. The aim of this thesis is to present the design, construction and testing of an experimental setup for the study of heat transfer enhancement in a turbulent boundary layer using cross-flow pulsed jets. The set-up is designed to generate and control pulsed jets, measure heat transfer and acquire all parameters related to wind tunnel flow and is also capable of varying the parameters of the pulsed jets, such as frequency, amplitude and the duty cycle, in order to study the effects on the increase in heat transfer. The thesis describes the design phases, the construction process and the final successful testing of the plant. The test results verify the functionality and accuracy of the set-up and ensure that it can be used to perform a full experimental campaign to investigate heat transfer enhancement using cross-flow pulsed jets in a turbulent layer boundary.