Studio e sviluppo di tecniche per la produzione di nanocompositi a matrice di alluminio

Foundry aluminum alloys play a fundamental role in several industrial fields, as they are employed in the production of several components in a wide range of applications. Moreover, these alloys can be employed as matrix for the development of Metal Matrix Composites (MMC), whose reinforcing phases may have different composition, shape and dimension. Ceramic particle reinforced MMCs are particular interesting due to their isotropic properties and their high temperature resistance. For this kind of composites, usually, decreasing the size of the reinforcing phase leads to the increase of mechanical properties. For this reason, in the last 30 years, the research has developed micro-reinforced composites at first, characterized by low ductility, and more recently nano-reinforced ones (the so called metal matrix nanocomposite, MMNCs). The nanocomposites can be obtained through several production routes: they can be divided in in-situ techniques, where the reinforcing phase is generated during the composite production through appropriate chemical reactions, and ex situ techniques, where ceramic dispersoids are added to the matrix once already formed. The enhancement in mechanical properties of MMNCs is proved by several studies; nevertheless, it is necessary to address some issues related to each processing route, as the control of process parameters and the effort to obtain an effective dispersion of the nanoparticles in the matrix, which sometimes actually restrict the use of these materials at industrial level. In this work of thesis, a feasibility study and implementation of production processes for Aluminum and AlSi7Mg based-MMNCs was conducted. The attention was focused on the in-situ process of gas bubbling, with the aim to obtain an aluminum oxide reinforcing phase, generated by the chemical reaction between the molten matrix and industrial dry air injected in the melt. Moreover, for what concerns the ex-situ techniques, stir casting process was studied and applied to introduce alumina nanoparticles in the same matrix alloys. The obtained samples were characterized through optical and electronic microscopy, then by micro-hardness tests, in order to evaluate possible improvements in mechanical properties of the materials.

Biogas and bio-hydrogen: production and uses. A review

The first part of this essay aims at investigating the already available and promising technologies for the biogas and bio-hydrogen production from anaerobic digestion of different organic substrates. One strives to show all the peculiarities of this complicate process, such as continuity, number of stages, moisture, biomass preservation and rate of feeding. The main outcome of this part is the awareness of the huge amount of reactor configurations, each of which suitable for a few types of substrate and circumstance. Among the most remarkable results, one may consider first of all the wet continuous stirred tank reactors (CSTR), right to face the high waste production rate in urbanised and industrialised areas. Then, there is the up-flow anaerobic sludge blanket reactor (UASB), aimed at the biomass preservation in case of highly heterogeneous feedstock, which can also be treated in a wise co-digestion scheme. On the other hand, smaller and scattered rural realities can be served by either wet low-rate digesters for homogeneous agricultural by-products (e.g. fixed-dome) or the cheap dry batch reactors for lignocellulose waste and energy crops (e.g. hybrid batch-UASB). The biological and technical aspects raised during the first chapters are later supported with bibliographic research on the important and multifarious large-scale applications the products of the anaerobic digestion may have. After the upgrading techniques, particular care was devoted to their importance as biofuels, highlighting a further and more flexible solution consisting in the reforming to syngas. Then, one shows the electricity generation and the associated heat conversion, stressing on the high potential of fuel cells (FC) as electricity converters. Last but not least, both the use as vehicle fuel and the injection into the gas pipes are considered as promising applications. The consideration of the still important issues of the bio-hydrogen management (e.g. storage and delivery) may lead to the conclusion that it would be far more challenging to implement than bio-methane, which can potentially “inherit” the assets of the similar fossil natural gas. Thanks to the gathered knowledge, one devotes a chapter to the energetic and financial study of a hybrid power system supplied by biogas and made of different pieces of equipment (natural gas thermocatalitic unit, molten carbonate fuel cell and combined-cycle gas turbine structure). A parallel analysis on a bio-methane-fed CCGT system is carried out in order to compare the two solutions. Both studies show that the apparent inconvenience of the hybrid system actually emphasises the importance of extending the computations to a broader reality, i.e. the upstream processes for the biofuel production and the environmental/social drawbacks due to fossil-derived emissions. Thanks to this “boundary widening”, one can realise the hidden benefits of the hybrid over the CCGT system.

Chemical composition modification of casting aluminium alloys for engine applications

The research activities were focused on evaluating the effect of Mo addition to mechanical properties and microstructure of A354 aluminium casting alloy. Samples, with increasing amount of Mo, were produced and heat treated. After heat treatment and exposition to high temperatures samples underwent microstructural and chemical analyses, hardness and tensile tests. The collected data led to the optimization of both casting parameters, for obtaining a homogeneous Mo distribution in the alloy, and heat treatment parameters, allowing the formation of Mo based strengthening precipitates stable at high temperature. Microstructural and chemical analyses highlighted how Mo addition in percentage superior to 0.1% wt. can modify the silicon eutectic morphology and hinder the formation of iron based β intermetallics. High temperature exposure curves, instead, showed that after long exposition hardness is slightly influenced by heat treatment while the effect of Mo addition superior to 0,3% is negligible. Tensile tests confirmed that the addition of 0.3%wt Mo induces an increase of about 10% of ultimate tensile strength after high temperature exposition (250°C for 100h) while heat treatments have slight influence on mechanical behaviour. These results could be exploited for developing innovative heat treatment sequence able to reduce residual stresses in castings produced with A354 modified with Mo.