CHARACTERIZATION OF THERMAL AND MECHANICAL PROPERTIES OF POLYPROPYLENE–BASED COMPOSITES FOR FUEL CELL BIPOLAR PLATES AND DEVELOPMENT OF EDUCATIONAL TOOLS IN HYDROGEN AND FUEL CELL TECHNOLOGIES

In this project we developed conductive thermoplastic resins by adding varying amounts of three different carbon fillers: carbon black (CB), synthetic graphite (SG) and multi–walled carbon nanotubes (CNT) to a polypropylene matrix for application as fuel cell bipolar plates. This component of fuel cells provides mechanical support to the stack, circulates the gases that participate in the electrochemical reaction within the fuel cell and allows for removal of the excess heat from the system. The materials fabricated in this work were tested to determine their mechanical and thermal properties. These materials were produced by adding varying amounts of single carbon fillers to a polypropylene matrix (2.5 to 15 wt.% Ketjenblack EC-600 JD carbon black, 10 to 80 wt.% Asbury Carbons’ Thermocarb TC-300 synthetic graphite, and 2.5 to 15 wt.% of Hyperion Catalysis International’s FIBRILTM multi-walled carbon nanotubes) In addition, composite materials containing combinations of these three fillers were produced. The thermal conductivity results showed an increase in both through–plane and in–plane thermal conductivities, with the largest increase observed for synthetic graphite. The Department of Energy (DOE) had previously set a thermal conductivity goal of 20 W/m·K, which was surpassed by formulations containing 75 wt.% and 80 wt.% SG, yielding in–plane thermal conductivity values of 24.4 W/m·K and 33.6 W/m·K, respectively. In addition, composites containing 2.5 wt.% CB, 65 wt.% SG, and 6 wt.% CNT in PP had an in–plane thermal conductivity of 37 W/m·K. Flexural and tensile tests were conducted. All composite formulations exceeded the flexural strength target of 25 MPa set by DOE. The tensile and flexural modulus of the composites increased with higher concentration of carbon fillers. Carbon black and synthetic graphite caused a decrease in the tensile and flexural strengths of the composites. However, carbon nanotubes increased the composite tensile and flexural strengths. Mathematical models were applied to estimate through–plane and in–plane thermal conductivities of single and multiple filler formulations, and tensile modulus of single–filler formulations. For thermal conductivity, Nielsen’s model yielded accurate thermal conductivity values when compared to experimental results obtained through the Flash method. For prediction of tensile modulus Nielsen’s model yielded the smallest error between the predicted and experimental values. The second part of this project consisted of the development of a curriculum in Fuel Cell and Hydrogen Technologies to address different educational barriers identified by the Department of Energy. By the creation of new courses and enterprise programs in the areas of fuel cells and the use of hydrogen as an energy carrier, we introduced engineering students to the new technologies, policies and challenges present with this alternative energy. Feedback provided by students participating in these courses and enterprise programs indicate positive acceptance of the different educational tools. Results obtained from a survey applied to students after participating in these courses showed an increase in the knowledge and awareness of energy fundamentals, which indicates the modules developed in this project are effective in introducing students to alternative energy sources.

Dynamic mechanical-thermal, microstructural and mechanical analysis of ultra-light polymer-metal composites: influence of forming

A really particular and innovative metal-polymer sandwich material is Hybrix. Hybrix is a product developed and manufactured by Lamera AB, Gothenburg, Sweden. This innovative hybrid material is composed by two relatively thin metal layers if compared to the core thickness. The most used metals are aluminum and stainless steel and are separated by a core of nylon fibres oriented perpendicularly to the metal plates. The core is then completed by adhesive layers applied at the PA66-metal interface that once cured maintain the nylon fibres in position. This special material is very light and formable. Moreover Hybrix, depending on the specific metal which is used, can achieve a good corrosion resistance and it can be cut and punched easily. Hybrix architecture itself provides extremely good bending stiffness, damping properties, insulation capability, etc., which again, of course, change in magnitude depending in the metal alloy which is used, its thickness and core thickness. For these reasons nowadays it shows potential for all the applications which have the above mentioned characteristic as a requirement. Finally Hybrix can be processed with tools used in regular metal sheet industry and can be handled as solid metal sheets. In this master thesis project, pre-formed parts of Hybrix were studied and characterized. Previous work on Hybrix was focused on analyze its market potential and different adhesive to be used in the core. All the tests were carried out on flat unformed specimens. However, in order to have a complete description of this material also the effect of the forming process must be taken into account. Thus the main activities of the present master thesis are the following: Dynamic Mechanical-Thermal Analysis (DMTA) on unformed Hybrix samples of different thickness and on pre-strained Hybrix samples, pure epoxy adhesive samples analysis and finally moisture effects evaluation on Hybrix composite structure.

Improvement of termite resistance, dimensional stability and mechanical properties of pine wood by paraffin impregnation

Paraffin has been used as surface protection of wood throughout the ages but its use for impregnation to improve wood resistance to biodegradation is recent. This study determined the main improvements on wood properties with paraffin impregnation. Healthy Pinus pinaster Ait. wood was impregnated with paraffin at different levels using a hot–cold process. Weight gain, equilibrium moisture content and dimensional stability (ASE) at 35 and 65 % relative humidity, termite durability against Reticulitermes grassei (Clément), bending strength, bending stiffness (MOE) and Janka hardness were determined. Density increased from 0.57 to 0.99, ASE ranged between 38–96 % and 16–71 % for 35 and 65 % relative humidity, respectively. Equilibrium moisture content decreased from 9.9 and 12.0 % to 0.8 and 3.6 % for 35 and 65 % relative humidity. Termite durability improved from level 4 to level 3 of attack, and higher termite mortality was found in treated wood (52 % against 17 %). Bending strength (MOR) increased with paraffin weight gain, reaching a 39 % increase. MOE also increased by about 13 % for wood with a weight gain around 80 %. Janka hardness increased significantly reaching about 40 % for wood with 80 % weight gain. Paraffin impregnated wood has improved properties with regard to equilibrium moisture content, dimensional stability and density, bending strength and Janka hardness, and resistance against termites.

Nonlinear Approaches to Attitude Control Using Magnetic and Mechanical Actuation

This thesis argues the attitude control problem of nanosatellites, which has been a challenging issue over the years for the scientific community and still constitutes an active area of research. The interest is increasing as more than 70% of future satellite launches are nanosatellites. Therefore, new challenges appear with the miniaturisation of the subsystems and improvements must be reached. In this framework, the aim of this thesis is to develop novel control approaches for three-axis stabilisation of nanosatellites equipped with magnetorquers and reaction wheels, to improve the performance of the existent control strategies and demonstrate the stability of the system. In particular, this thesis is focused on the development of non-linear control techniques to stabilise full-actuated nanosatellites, and in the case of underactuation, in which the number of control variables is less than the degrees of freedom of the system. The main contributions are, for the first control strategy proposed, to demonstrate global asymptotic stability derived from control laws that stabilise the system in a target frame, a fixed direction of the orbit frame. Simulation results show good performance, also in presence of disturbances, and a theoretical selection of the magnetic control gain is given. The second control approach presents instead, a novel stable control methodology for three-axis stabilisation in underactuated conditions. The control scheme consists of the dynamical implementation of an attitude manoeuvre planning by means of a switching control logic. A detailed numerical analysis of the control law gains and the effect on the convergence time, total integrated and maximum torque is presented demonstrating the good performance and robustness also in the presence of disturbances.

Aging assessment of polyethylene-based insulated low-voltage cables for nuclear applications

This thesis aims at investigating the evolution of physico-chemical and electrical properties relevant to low-voltage power cables for nuclear application when subjected to typical nuclear power plant (NPP) environments i.e., to gamma radiation and high temperature. This research is part of the European Project Horizon 2020 TeaM Cables, which aims at providing a novel methodology for efficient and reliable NPP cable aging management to NPP operators. The analyzed samples consist of both coaxial and twisted pair cables with different polymeric compounds used as primary insulation. Insulating materials are based on the same silane cross-linked polyethylene matrix with different additives and fillers. In order to characterize the material response to the environmental stresses, various experimental techniques have been used. These characterizations range from the microscale chemical response e.g. by FTIR, OIT and DSC, to the macroscale electrical and mechanical behavior. A significant part of this Thesis is given to the correlation of the response to aging among the different measured properties. It has been shown that it could be possible to connect both the chemical and mechanical properties of the investigated XLPE cables with the electrical ones. In particular, the high-frequency dielectric response allows an effective monitoring of both the early periods of aging, controlled by the antioxidant consumption kinetics, and then the subsequent oxidation of the polymer matrix. Therefore, dielectric spectroscopy showed to be capable of assessing the LV cable aging state and, it might be used as an aging marker for cable diagnostic. The last part of the manuscript focuses on the building of a predictive modelling approach of LV cable conditions subjected to radio-chemical aging. It resulted into obtaining a lifetime curve which relates the aging factor to which the cable is subjected to, namely the dose rate, with the limit value of the considered electrical property (tanδ).

Additive Manufacturing by LPBF and WAAM of metals: correlation between production process, microstructure and mechanical properties

In the most recent years, Additive Manufacturing (AM) has drawn the attention of both academic research and industry, as it might deeply change and improve several industrial sectors. From the material point of view, AM results in a peculiar microstructure that strictly depends on the conditions of the additive process and directly affects mechanical properties. The present PhD research project aimed at investigating the process-microstructure-properties relationship of additively manufactured metal components. Two technologies belonging to the AM family were considered: Laser-based Powder Bed Fusion (LPBF) and Wire-and-Arc Additive Manufacturing (WAAM). The experimental activity was carried out on different metals of industrial interest: a CoCrMo biomedical alloy and an AlSi7Mg0.6 alloy processed by LPBF, an AlMg4.5Mn alloy and an AISI 304L austenitic stainless steel processed by WAAM. In case of LPBF, great attention was paid to the influence that feedstock material and process parameters exert on hardness, morphological and microstructural features of the produced samples. The analyses, targeted at minimizing microstructural defects, lead to process optimization. For heat-treatable LPBF alloys, innovative post-process heat treatments, tailored on the peculiar hierarchical microstructure induced by LPBF, were developed and deeply investigated. Main mechanical properties of as-built and heat-treated alloys were assessed and they were well-correlated to the specific LPBF microstructure. Results showed that, if properly optimized, samples exhibit a good trade-off between strength and ductility yet in the as-built condition. However, tailored heat treatments succeeded in improving the overall performance of the LPBF alloys. Characterization of WAAM alloys, instead, evidenced the microstructural and mechanical anisotropy typical of AM metals. Experiments revealed also an outstanding anisotropy in the elastic modulus of the austenitic stainless-steel that, along with other mechanical properties, was explained on the basis of microstructural analyses.

Characterization of an international tetraploid wheat germplasm including landraces and primitive wheat towards improved resilience to abiotic and biotic stresses and quality

This thesis aimed to characterise two large tetraploid germplasm collections. The Global Durum Panel, involving modern cultivars and landrances and the Tetraploid Global Collection which comprises all the tetraploid wheat subgroups. Two distinct parallel studies were carried out. The first is focused on the characterisation of both collection for yield and quality related traits. The panel were phenotyped for two consecutive years each. In this phase the following traits were collected: the number of fertile spikelets per spike, the number of fertile florets of central spikelet for the spike-related traits. The following grain related traits were also phenotyped: the thousand kernel weight, the average grain area, average grain length, average grain width, grain brightness, grain redness, grain yellowness. GWAS analysis were performed for each collected trait and major QTLs were subjected to candidate gene analysis. Major QTLs emerging from GWA study were located on chromosome 2A with a strong bibliographic evidence for grain number-related traits such as the fertile spikelet number, the number of fertile florets per central spikelet. On the other hand two evident peaks were detected on chromosomes 6A and 7B for grain size and weight related traits. The second work was focused on the characterisation of the Global Durum Panel for root system architecture components, namely the root growth angle. GWAS analysis was perfomed and three major QTLs were detected on chromosome 2A, 6A and 7A. These three QTLs all have a bibliographic evidence.

Influence of cultivar choice, sowing date and abiotic stresses on tocopherol content and composition in Camelina sativa (L.) Crantz

In Europe, the current demand for vegetable oils and the need to find alternative crops for the regions most affected by climate change (i.e., Mediterranean basin) may be a launchpad for camelina [Camelina sativa (L.) Crantz] to be steadily introduced in European cropping systems. Camelina is mainly known for the unique composition of its oil, with a fatty acids profile including more than 50% content of essential linoleic and linolenic fatty acids, and a high tocopherol content. Being tocopherols part of the vitamin E family of antioxidants, the added value of growing camelina in harsh environments could be the enhancement of tocopherol content in camelina oil, thus having a more stable and nutritionally valuable product. With the final purpose of fully valorize camelina as a tolerant, valuable-oil producing crop for the Mediterranean basin, the main aim of this study was to investigate whether and how sowing date, cultivar choice, and abiotic stresses can affect tocopherol content and composition in camelina oil. The results showed that cultivar choice and growing conditions influenced total tocopherol, γ-tocopherol, and α-tocopherol contents. Moreover, heat stress trial revealed that high temperature increased α-tocopherol content, while no effect was observed in total tocopherols and in γ-tocopherol content. Finally, drought increased total tocopherols in camelina, and in drought-sensitive lines an increase in α-tocopherol was observed. This study allowed to acquire awareness on camelina resistance to abiotic stresses, coupled with a better knowledge on tocopherol content and composition in relation to cultivar, sowing date, and abiotic stresses. This will have an impact for the introduction of camelina as an alternative crop in harsher environments, such as the Mediterranean basin, to produce an oil suitable for food, feed, and industrial applications.

High-strength steels manufactured via Laser Powder Bed Fusion: effect of post-process heat treatments and surface finishing on microstructure and mechanical properties

Laser Powder Bed Fusion (LPBF) permits the manufacturing of parts with optimized geometry, enabling lightweight design of mechanical components in aerospace and automotive and the production of tools with conformal cooling channels. In order to produce parts with high strength-to-weight ratio, high-strength steels are required. To date, the most diffused high-strength steels for LPBF are hot-work tool steels, maraging and precipitation-hardening stainless steels, featuring different composition, feasibility and properties. Moreover, LPBF parts usually require a proper heat treatment and surface finishing, to develop the desired properties and reduce the high roughness resulting from LPBF. The present PhD thesis investigates the effect of different heat treatments and surface finishing on the microstructure and mechanical properties of a hot-work tool steel and a precipitation-hardening stainless steel manufactured via LPBF. The bibliographic section focuses on the main aspects of LPBF, hot-work tool steels and precipitation-hardening stainless steels. The experimental section is divided in two parts. Part A addresses the effect of different heat treatments and surface finishing on the microstructure, hardness, tensile and fatigue behaviour of a LPBF manufactured hot-work tool steel, to evaluate its feasibility for automotive and racing components. Results indicated the possibility to achieve high hardness and strength, comparable to the conventionally produced steel, but a great sensitivity of fatigue strength on defects and surface roughness resulting from LPBF. Part B investigates the effect of different heat treatments on the microstructure, hardness, tensile and notch-impact behaviour of a LPBF produced precipitation-hardening stainless steel, to assess its feasibility for tooling applications. Results indicated the possibility to achieve high hardness and strength also through a simple Direct Aging, enabling heat treatment simplification by exploiting the microstructural features resulting from LPBF.

Evaluation of the microstructural pattern and mechanical behaviour of human metastatic vertebrae

La spina dorsale è uno dei principali siti di sviluppo di metastasi ossee. Queste alterano sia la composizione strutturale che il comportamento meccanico delle vertebre metastatiche, riducendone la resistenza meccanica ed aumentandone il rischio di rottura. Questo studio ha valutato la composizione microstrutturale ed il comportamento meccanico a rottura in specifiche regioni all’interno di vertebre metastatiche. 11 segmenti vertebrali da cadavere, costituiti da una vertebra sana ed una con metastasi (litica, mista o blastica), sono stati testati con carichi graduali di compressione e scansionati con microCT. Le deformazioni interne sono state misurate tramite un algoritmo globale di Digital Volume Correlation (DVC). I risultati dall’analisi microstrutturale hanno mostrato l’ influenza sulla microstruttura delle diverse tipologie di metastasi in corrispondenza della lesione, mentre le caratteristiche microstrutturali nelle regioni intorno alla lesione sono risultate simili a quelle delle vertebre sane. L’analisi delle deformazioni ha inoltre permesso di valutare l’ effetto delle diverse tipologie di metastasi nel compromettere la stabilità spinale. Le vertebre con metastasi litiche hanno raggiunto deformazioni maggiori in corrispondenza della lesione, regione meccanicamente più debole e con una microstruttura maggiormente compromessa a causa della metastasi. Le vertebre con metastasi blastiche hanno raggiunto deformazioni minori nella lesione, regione che ha mostrato una maggiore resistenza meccanica ai carichi, e deformazioni maggiori nelle zone più lontane. Le vertebre con metastasi miste hanno mostrato un comportamento meccanico non univoco, legato alla predominanza di una lesione sull’altra. Infatti, la posizione e la proporzione tra le due lesioni sembra influenzare il comportamento meccanico. I risultati di questo studio, una volta generalizzati, potrebbero portare alla spiegazione delle cause di instabilità meccanica nelle vertebre metastatiche.

Design, fabrication and mechanical characterization of a structural node made using Wire and Arc Additive Manufacturing (WAAM) technology

Additive Manufacturing (AM), also known as “3D printing”, is a recent production technique that allows the creation of three-dimensional elements by depositing multiple layers of material. This technology is widely used in various industrial sectors, such as automotive, aerospace and aviation. With AM, it is possible to produce particularly complex elements for which traditional techniques cannot be used. These technologies are not yet widespread in the civil engineering sector, which is slowly changing thanks to the advantages of AM, such as the possibility of realizing elements without geometric restrictions, with less material usage and a higher efficiency, in particular employing Wire-and-Arc Additive Manufacturing (WAAM) technology. Buildings that benefit most from AM are all those structures designed using form-finding and free-form techniques. These include gridshells, where joints are the most critical and difficult elements to design, as the overall behaviour of the structure depends on them. It must also be considered that, during the design, the engineer must try to minimize the structure's own weight. Self-weight reductions can be achieved by Topological Optimization (TO) of the joint itself, which generates complex geometries that could not be made using traditional techniques. To sum up, weight reductions through TO combined with AM allow for several potential benefits, including economic ones. In this thesis, the roof of the British Museum is considered as a case study, analysing the gridshell structure of which a joint will be chosen to be designed and manufactured, using TO and WAAM techniques. Then, the designed joint will be studied in order to understand its structural behaviour in terms of stiffness and strength. Finally, a printing test will be performed to assess the production feasibility using WAAM technology. The computational design and fabrication stages were carried out at Technische Universität Braunschweig in Germany.

Utilização de Cabos de alta Temperatura em linhas Aéreas em Média Tensão

A presente dissertação teve como objetivo fazer uma análise da viabilidade técnica da utilização dos condutores de alta temperatura nas linhas aéreas de MT, identificar vantagens, analisar inconvenientes, e estabelecer um comparativo a custos médios com as soluções convencionais. Foi efetuado o estudo de um caso real da EDP Distribuição que consistia na necessidade do aumento da capacidade de transporte de energia da linha aérea a 15 kV Espinho-Sanguedo. Neste foi ponderada a solução onde se poderia efetuar passagem de linha simples para linha dupla em alumínio-aço (AA) 160 mm2 ou a solução alternativa e inovadora de substituição dos condutores existentes por condutores de alta temperatura ACCC 182 mm2. Para isso foram efetuados cálculos e também criada uma ferramenta de apoio à decisão, para validação dos mesmos, com o intuito de mais tarde poder ser aplicada nas linhas aéreas em Média Tensão em todo o país e, sempre que necessário, se possa fazer um estudo de ponderação técnica de forma sistemática e estruturada. Neste trabalho estão identificadas as vantagens, foram relatados os inconvenientes, e estabeleceu-se um comparativo a custos médios da utilização de condutores de alta temperatura com as soluções convencionais. Antes de poder ser realizado um estudo do caso concreto da Linha aérea Espinho-Sanguedo foi necessário um aprofundamento do estado da arte no que diz respeito à comparação entre o cabo de alta temperatura ACCC e o cabo convencional ACSR, sendo este o mais utilizado nas linhas aéreas em MT. Os cabos de alta temperatura trouxeram inovações neste tema de transporte de energia, e como tal surgiu a necessidade de um estudo mais aprofundado da sua constituição, destacando o seu núcleo formado pelo compósito de fibra de carbono e fibra de vidro. Foi também analisado vantagens e desvantagens do cabo de alta temperatura e até mesmo situações onde a sua aplicação poderá ser vantajosa, de modo a tirar proveito das suas caraterísticas em que se destacam altas temperaturas de funcionamento e flechas reduzidas. Para elaborar um projeto de uma linha aérea em média tensão é necessário considerar a legislação em vigor, os aspetos ambientais e económicos, respeitando e garantindo as premissas do cálculo elétrico e mecânico. Economicamente este tipo de cabo (ACCC) é mais dispendioso do que os convencionais, no entanto o estudo realizado permitiu perceber que a sua implementação técnica é vantajosa em linhas aéreas de elevada capacidade de transporte de energia, sobretudo nos casos onde serão necessárias instalar linhas duplas ou linhas simples de seções elevadas. Devido às suas caraterísticas mecânicas, estes cabos permitem melhorar as linhas na sua dimensão, podendo diminuir o número de apoios a instalar, podendo diminuir a robustez dos apoios e permitir maior facilidade na montagem. Estas vantagens traduzem-se em menores impactos ambientais e permitem sobretudo reduzir os constrangimentos com os proprietários dos terrenos onde os apoios são implantados.

Estudo das propriedades físicas fundamentais de filmes finos intermetálicos do tipo Ti-Me (Me = Al, Au) na funcionalização de elétrodos - sensores para dispositivos biomédicos

Dissertação de mestrado integrado em Engenharia de Materiais