Optimization of an innovative T6 heat treatment for the AlSi10Mg alloy processed by Laser-based Powder Bed Fusion: effect on microstructure, mechanical properties, and tribological behavior

Laser-based Powder Bed Fusion (L-PBF) technology is one of the most commonly used metal Additive Manufacturing (AM) techniques to produce highly customized and value-added parts. The AlSi10Mg alloy has received more attention in the L-PBF process due to its good printability, high strength/weight ratio, corrosion resistance, and relatively low cost. However, a deep understanding of the effect of heat treatments on this alloy's metastable microstructure is still required for developing tailored heat treatments for the L-PBF AlSi10Mg alloy to overcome the limits of the as-built condition. Several authors have already investigated the effects of conventional heat treatment on the microstructure and mechanical behavior of the L-PBF AlSi10Mg alloy but often overlooked the peculiarities of the starting supersatured and ultrafine microstructure induced by rapid solidification. For this reason, the effects of innovative T6 heat treatment (T6R) on the microstructure and mechanical behavior of the L-PBF AlSi10Mg alloy were assessed. The short solution soaking time (10 min) and the relatively low temperature (510 °C) reduced the typical porosity growth at high temperatures and led to a homogeneous distribution of fine globular Si particles in the Al matrix. In addition, it increased the amount of Mg and Si in the solid solution available for precipitation hardening during the aging step. The mechanical (at room temperature and 200 °C) and tribological properties of the T6R alloy were evaluated and compared with other solutions, especially with an optimized direct-aged alloy (T5 alloy). Results showed that the innovative T6R alloy exhibits the best mechanical trade-off between strength and ductility, the highest fatigue strength among the analyzed conditions, and interesting tribological behavior. Furthermore, the high-temperature mechanical performances of the heat-treated L-PBF AlSi10Mg alloy make it suitable for structural components operating in mild service conditions at 200 °C.

Radiation characteristics enhancement of planar structures using metasurfaces

In this thesis, the focus is on utilizing metasurfaces to improve radiation characteristics of planar structures. The study encompasses various aspects of metasurface applications, including enhancing antenna radiation characteristics and manipulating electromagnetic (EM) waves, such as polarization conversion and anomalous reflection. The thesis introduces the design of a single-port antenna with dual-mode operation, integrating metasurfaces. This antenna serves as the front-end for a next-generation tag, functioning as a position sensor with identification and energy harvesting capabilities. It operates in the lower European Ultra-Wideband (UWB) frequency range for communication/localization and the UHF band for wireless energy reception. The design aims for a low-profile stack-up that remains unaffected by background materials. Researchers worldwide are drawn to metasurfaces due to their EM wave manipulation capabilities. The thesis also demonstrates how a High-Impedance Surface (HIS) can enhance the antenna's versatility through metasurface application, including conformal design using 3D-printing technology, ensuring adaptability for various deformation and tracking/powering scenarios. Additionally, the thesis explores two distinct metasurface applications. One involves designing an angularly stable super-wideband Circular Polarization Converter (CPC) operating from 11 to 35GHz with an impressive relative impedance bandwidth of 104.3%. The CPC shows a stable response even at oblique incidences up to 40 degrees, with a Peak Cross-Polarization Ratio (PCR) exceeding 62% across the entire band. The second application focuses on an Intelligent Reflective Surface (IRS) capable of redirecting incoming waves in unconventional directions. Tunability is achieved through an artificially developed ferroelectric material (HfZrO) and distributed capacitive elements (IDC) to fine-tune impedance and phase responses at the meta-atom level. The IRS demonstrates anomalous reflection for normal incident waves. These innovative applications of metasurfaces offer promising advancements in antenna design, EM wave manipulation, and versatile wireless communication systems.

Numerical simulation of the flow and performance evaluation of an aerospike engine

The main focus of this work is to define a numerical methodology to simulate an aerospike engine and then to analyse the performance of DemoP1, which is a small aerospike demonstrator built by Pangea Aerospace. The aerospike is a promising solution to build more efficient engine than the actual one. Its main advantage is the expansion adaptation that allows to reach the optimal expansion in a wide range of ambient pressures delivering more thrust than an equivalent bell-shaped nozzle. The main drawbacks are the cooling system design and the spike manufacturing but nowadays, these issues seem to be overcome with the use of the additive manufacturing method. The simulations are performed with dbnsTurbFoam which is a solver of OpenFOAM. It has been designed to simulate a supersonic compressible turbulent flow. This work is divided in four chapters. The first one is a short introduction. The second one shows a brief summary of the theoretical performance of the aerospike. The third one introduces the numerical methodology to simulate a compressible supersonic flow. In the fourth chapter, the solver has been verified with an experiment found in literature. And in the fifth chapter, the simulations on DemoP1 engine are illustrated.

Progetto preliminare e modellazione CAD di UAV ad ala rotante per impieghi agricoli

In questa tesi viene descritto uno studio preliminare su un velivolo ad ala rotante UAV (Unmanned Aerial Veichle) per supportare l'agricoltura di precisione. E' stato implementato in ambiente Matlab un semplice modello matematico per stimare la trazione del rotore principale in un elicottero. Successivamente, è stata presa in considerazone una meccanica commerciale per modellismo che potrebbe essere adottata per sveltire i tempi di sviluppo di questo UAV: la Graupner UNI-Mechanics 2000. E' stato, quindi, modellato al CAD un prototipo di struttura da realizzare tramite tecniche di Additive Manufacturing: questa parte è stata concepita per essere collegata alla meccanica dell'elicottero e può ospitare due taniche contenenti le sostanze da irrorare sulle colture. A livello di sviluppo futuro, si propone di applicare tecniche di ottimizzazione topologica alla struttura di collegamento per ottenere uno sfruttamento ottimale del materiale e ridurre le masse di questo componente.

Collection and real-time analysis of images from aircraft to support civil protection operational activities

This report describes the realization of a system, in which an object detection model will be implemented, whose aim is to detect the presence of people in images. This system could be used for several applications: for example, it could be carried on board an aircraft or a drone. In this case, the system is designed in such a way that it can be mounted on light/medium weight helicopters, helping the operator to find people in emergency situations. In the first chapter the use of helicopters for civil protection is analysed and applications similar to this case study are listed. The second chapter describes the choice of the hardware devices that have been used to implement a prototype of a system to collect, analyse and display images. At first, the PC necessary to process the images was chosen, based on the characteristics of the algorithms that are necessary to run the analysis. In the further, a camera that could be compatible with the PC was selected. Finally, the battery pack was chosen taking into account the electrical consumption of the devices. The third chapter illustrates the algorithms used for image analysis. In the fourth, some of the requirements listed in the regulations that must be taken into account for carrying on board all the devices have been briefly analysed. In the fifth chapter the activity of design and modelling, with the CAD Solidworks, the devices and a prototype of a case that will house them is described. The sixth chapter discusses the additive manufacturing, since the case was printed exploiting this technology. In the seventh chapter, part of the tests that must be carried out on the equipment to certificate it have been analysed, and some simulations have been carried out. In the eighth chapter the results obtained once loaded the object detection model on a hardware for image analyses were showed. In the ninth chapter, conclusions and future applications were discussed.

Studio del comportamento meccanico e tribologico della lega AlSi10Mg prodotta mediante Laser-based Powder Bed Fusion sottoposta ad un ciclo tecnologico ottimizzato

AlSi10Mg alloy is one of the most widely used alloys for producing structural components by Laser-based Powder Fusion (L-PBF) technology due to the high mechanical and technological properties. The present work aims to characterize mechanically and tribologically the L-PBF AlSi10Mg alloy subjected to both heat treatment and surface modification cycles. Specifically, the effects of three heat treatments on the tribological and mechanical properties of the alloy were analyzed: T5 (artificial aging at 160 °C for 4 h), T6 rapid solution heat treatment (solution heat treatment at 510 °C for 1h and aging at 160 °C for 6 h), and T6 benchmark (solution heat treatment at 540 °C for 1h and aging at 160 °C for 4 h), the latter used as a benchmark. The study highlighted how the better balance between strength and ductility properties induced by the introduction of heat treatments leads to lower wear resistance and not significant variations in the friction coefficient of the alloy. The tribological and mechanical behavior of the alloy coated with two different coating structures, consisting of (i) chemical Ni (Ni-P) and (ii) Ni-P + DLC, was also evaluated. The goal was the identification of a deposition cycle such as to guarantee the optimization of the mechanical and tribological behavior of the alloy. The Ni-P coating provided good wear resistance but an increase in the coefficient of friction. In contrast, using the DLC top coating resulted in excellent tribological performance in wear resistance and friction coefficient. The samples characterized by the Ni-P + DLC multilayer coating were subsequently subjected to mechanical characterization. The results obtained highlighted problems of adhesion and incipient breaking of the material due to the different mechanical behavior of the coating, considerably reducing the mechanical performance of the alloy coated with Ni-P+DLC multilayer solution compared to the specimens in the un-coated condition.

Caratterizzazione meccanica ad alta temperatura dell'acciaio inossidabile AISI 316L prodotto con processo additivo

Analisi meccanica e microstrutturale a temperatura ambiente e alta temperatura (400 °C) dell'acciaio inossidabile AISI 316L prodotto tramite additive manufacturing (Laser Powder Bed Fusion) e rivestito con un sistema multistrato composto da nichelatura al fosforo e diamond like carbon. Il materiale è stato testato meccanicamente tramite prove di trazione, fatica a basso numero di cicli e durezza. Queste hanno dimostrato come il rivestimento non modifica significativamente le proprietà a trazione del materiale (sia a 20°C che a 400 °C) mentre allunga notevolmente la vita a fatica del provino a temperatura ambiente. Le analisi di durezza hanno evidenziato il diverso comportamento del rivestimento a temperatura ambiente e a 400 °C in quanto, alla temperatura di 300 °C, subisce una ricristallizzazione che ne determina un indurimento. L'analisi microstrutturale ha previsto l'osservazione del materiale al microscopio ottico ed elettronico a scansione FEG-SEM, la quale ha permesso di identificare i melt pool, grani colonnari e struttura cellulare che compongono il materiale. La struttura cellulare scompare a 400 °C mentre i melt pool ed i grani colonnari restano invariati. Oltre a queste analisi sono state svolte anche delle osservazioni per quanto riguarda le superfici di frattura del materiale le quali hanno mostrato una tipologia di frattura duttile nei provini di trazione mentre i campioni a fatica presentano una tipica frattura a fatica, ovvero che comprende un innesco, una zona di propagazione della cricca ed una zona di rottura di schianto. I campioni rivestiti presentavano l'innesco nella zona interfacciale tra substrato e rivestimento a causa delle tensioni residue, nonostante l'adesione del rivestimento con l'acciaio fosse ottimale.

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.

Effetto della sabbiatura sul comportamento a fatica della lega AlSi10Mg prodotta con Laser Powder Bed Fusion e trattata termicamente

La tesi in oggetto ha lo scopo di determinare l’effetto della sabbiatura sul comportamento a fatica della lega AlSi10Mg prodotta mediante Laser Powder Bed Fusion e trattata termicamente. I parametri di processo e di trattamento termico (T5 e T6) sono stati precedentemente ottimizzati. Al fine di determinare l’effetto della sabbiatura su topografia superficiale e microstruttura dei campioni, si sono condotte molteplici analisi avvalendosi di strumenti quali profilometria, microscopia ottica ed in scansione, analisi di tensioni residue con diffrazione a raggi X e prove di durezza. Attraverso prove di fatica per flessione rotante, eseguite secondo il metodo Stair-Case per la determinazione della resistenza a fatica, e successiva caratterizzazione delle superfici di frattura si vuole correlare il difetto killer, ossia quello responsabile del cedimento per fatica, alle caratteristiche morfologiche e microstrutturali. Il difetto killer viene caratterizzato in termini di dimensione e distanza dalla superficie e per mostrare la relazione fra la dimensione del difetto killer e la resistenza a fatica si adotta il diagramma di Kitagawa-Takahashi con modellazione di Murakami ed EL Haddad. Si è evidenziato che tutti i difetti killer sono riconducibili a lack-of-fusion con dimensione superiore ai 100 μm ad una profondità compresa fra i 150 e i 200 μm, indipendentemente dal trattamento termico o meccanico applicato. In termini di fatica si osserva che il trattamento T6 conferisce al materiale migliori proprietà rispetto a quello T5. Il processo di sabbiatura, confrontato con quello di lucidatura superficiale, ha portato a miglioramenti in termini di durezza e tensioni residue di compressione, ma si è rivelato quasi ininfluente sulla resistenza a fatica. Sulla base di quanto sopra, si conferma la possibilità di applicazione della sabbiatura in ambito industriale a componenti meccanici, anche in sostituzione della lucidatura, ottenendo un beneficio anche economico.

Inkjet printing technology for flexible pressure sensors

Tese de Doutoramento Ciência e Engenharia de Polímeros e Compósitos.

Development of procedures for the design, optimization and manufacturing of customized orthopaedic and trauma implants: Geometrical/anatomical modelling from 3D medical imaging

Tese de Doutoramento (Programa Doutoral em Engenharia Biomédica)

Fabrication additive ou Impression 3D. Aperçus sur une variation terminographique

Materiaalia lisäävä valmistus eli 3D-tulostus on valmistusmenetelmä, jossa kappale tehdään 3D-mallin pohjalta materiaalikerroksia lisäämällä, käyttäen useita tekniikoita ja materiaaleja. Menetelmää sovelletaan useilla teollisuuden aloilla. Lisääviä valmistustekniikoita on kehitetty 1990-luvun alkupuolelta lähtien, ja ne monipuolistuvat jatkuvasti. Tässä pro gradu -tutkielmassa tutkitaan sovellusalan terminologian kehitystä vertailevilla menetelmillä ja luodaan kolmikielinen sanasto alan asiantuntijoille, joita edustaa Suomessa FIRPA ry. Sanaston kielet ovat englanti, ranska ja suomi. Terminologian tutkimus on perinteisesti keskittynyt sanastotyöhön ja käsiteanalyysiin, sen sijaan termihistorian tutkimus on ollut vähäisempää. Tässä työssä on tehty vertailevaa termitutkimusta sekä sanastotyön että termihistorian näkökulmista. Vertailutasoja ovat termien merkityksen muuttuminen, vertailu pivot-kielen suhteen ja kielikohtaisten ominaisuuksien tarkastelu termien muotoutumisessa. Tutkittavia asioita ovat sanastokäsitteiden väliset suhteet, synonyymien, varianttien ja uudissanojen moninaisuus, ja termien yleiskielistyminen. Samalla pohditaan muita termien muuttumiseen vaikuttavia syita. Tärkeimpänä lähteenä käytetään Wohlersin vuosiraportteja, jotka kuvaavat kattavasti koko teollisuudenalaa. Koska englannin pivot-vaikutus on voimakasta teknisillä aloilla, omankielisen terminologian kehittyminen vaatii tietoista terminologiatyötä ja aktiivista omankielisten termien käyttöä. Terminologian vakiintumista voidaan arvioida termivarianttien ja uudissanojen määristä, sekä termien yleiskielistymisestä. Terminologia muuttuu jatkuvasti toimialan kehittyessä ja vaatii säännöllistä päivittämistä. Termihistorian tunteminen tukee sanastotyön termivalintoja. Alan asiantuntijat ovat vastuussa omasta terminologiastaan, ja heidän aktiivisuutensa on tärkeää sen kehittämisessä. Toteutettu sanasto on tämän pro gradu -tutkielman liitteenä ja se julkaistaan myös FIRPA ry:n Internet-sivustolla. Suomenkielinen osio sanastosta on ensimmäinen laaja suomeksi julkaistu materiaalia lisäävän valmistuksen sanasto.

Energy harvesting from piezoelectric devices embedded in a 3D printed wing

This thesis work has been carried out at Clarkson University in Potsdam NY, USA and involved the design of a low elongation wing, consisting of parts made by polylactide (PLA) using the fused deposition model (FDM) technology of Rapid Prototyping, then assembled together in a thin aluminum spar. The aim of the research is to evaluate the feasibility of collecting electrical energy by converting mechanical energy from the vibration of the wing flutter. With this aim piezoelectric stripes were glued in the inner part of the wing, as well as on the aluminum spar, as monomorphic configuration. During the phases of the project, particular attention was given to the geometry and the materials used, in order to trigger the flutter for low flow velocity. The CAD software SolidWorks® was used for the design of the wing and then the drawings were sent to the Clarkson machine shop in order to to produce the parts required by the wing assembly. FEM simulations were performed, using software MSC NASTRAN/PATRAN®, to evaluate the stiffness of the whole wing as well as the natural vibration modes of the structure. These data, in a first approximation, were used to predict the flutter speed. Finally, experimental tests in the Clarkson wind tunnel facility were carried out in order to validate the results obtained from FEM analysis. The power collected by the piezoelectrics under flutter condition was addressed by tuning the resistors downstream the electronic circuit of the piezoelectrics.

3D-based reconstruction using growing neural gas landmark: application to rapid prototyping in shoe last manufacturing

Customizing shoe manufacturing is one of the great challenges in the footwear industry. It is a production model change where design adopts not only the main role, but also the main bottleneck. It is therefore necessary to accelerate this process by improving the accuracy of current methods. Rapid prototyping techniques are based on the reuse of manufactured footwear lasts so that they can be modified with CAD systems leading rapidly to new shoe models. In this work, we present a shoe last fast reconstruction method that fits current design and manufacturing processes. The method is based on the scanning of shoe last obtaining sections and establishing a fixed number of landmarks onto those sections to reconstruct the shoe last 3D surface. Automated landmark extraction is accomplished through the use of the self-organizing network, the growing neural gas (GNG), which is able to topographically map the low dimensionality of the network to the high dimensionality of the contour manifold without requiring a priori knowledge of the input space structure. Moreover, our GNG landmark method is tolerant to noise and eliminates outliers. Our method accelerates up to 12 times the surface reconstruction and filtering processes used by the current shoe last design software. The proposed method offers higher accuracy compared with methods with similar efficiency as voxel grid.

Development of an e-business selection framework for manufacturing SMEs : a study of the printing industry

The aim of the research is to develop an e-business selection framework for small and medium enterprises (SMEs) by integrating established techniques in planning. The research is case based, comprising four case studies carried out in the printing industry for the purpose of evaluating the framework. Two of the companies are from Singapore, while the other two are from Guangzhou, China and Jinan, China respectively. To determine the need of an e-business selection framework for SMEs, extensive literature reviews were carried out in the area of e-business, business planning frameworks, SMEs and the printing industry. An e-business selection framework is then proposed by integrating the three established techniques of the Balanced Scorecard (BSC), Value Chain Analysis (VCA) and Quality Function Deployment (QFD). The newly developed selection framework is pilot tested using a published case study before actual evaluation is carried out in four case study companies. The case study methodology was chosen because of its ability to integrate diverse data collection techniques required to generate the BSC, VCA and QFD for the selection framework. The findings of the case studies revealed that the three techniques of BSC, VCA and QFD can be integrated seamlessly to complement on each other’s strengths in e-business planning. The eight-step methodology of the selection framework can provide SMEs with a step-by-step approach to e-business through structured planning. Also, the project has also provided better understanding and deeper insights into SMEs in the printing industry.