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.

Development and testing of innovative methodologies for modelling and control of normal and knocking combustion and implementation of novel rapid prototyping solutions

The thesis work deals with topics that led to the development of innovative control-oriented models and control algorithms for modern gasoline engines. Knock in boosted spark ignition engines is the widest topic discussed in this document because it remains one of the most limiting factors for maximizing combustion efficiency in this kind of engine. First chapter is thus focused on knock and a wide literature review is proposed to summarize the preliminary knowledge that even represents the background and the reference for discussed activities. Most relevant results achieved during PhD course in the field of knock modelling and control are then presented, describing every control-oriented model that led to the development of an adaptive model-based combustion control system. The complete controller has been developed in the context of the collaboration with Ferrari GT and it allowed to completely redefine the knock intensity evaluation as well as the combustion phase control. The second chapter is focused on the activity related to a prototyping Port Water Injection system that has been developed and tested on a turbocharged spark ignition engine, within the collaboration with Magneti Marelli. Such system and the effects of injected water on the combustion process were then modeled in a 1-D simulation environment (GT Power). Third chapter shows the development and validation of a control-oriented model for the real-time calculation of exhaust gas temperature that represents another important limitation to the performance increase in modern boosted engines. Indeed, modelling of exhaust gas temperature and thermocouple behavior are themes that play a key role in the optimization of combustion and catalyst efficiency.

Numerical modelling of axially loaded piled foundations with physical tests validation

L'oggetto della tesi è la modellazione numerica di pali di fondazione per turbine eoliche in ambiente offshore. Il metodo di modellazione comprende l'interpretazione di prove CPT per l'estrapolazione dei parametri geotecnici del terreno, la creazione di un modello dell'interazione tra struttura e terreno tramite il software agli elementi finiti Abaqus, la sua verifica, l'ottimizzazione dell'estensione del modello del terreno e della mesh e la simulazione numerica del comportamento di pali caricati assialmente in compressione. Grazie al confronto con i risultati di test su modelli fisici, eseguiti nel laboratorio dell'istituto Fraunhofer IWES di Hannover, di tre pali aventi la stessa geometria ma installati in punti con diverse condizioni di compattazione della sabbia, è stata possibile la messa a punto di una strategia di simulazione più accurata possibile e la sua validazione. A conclusione del lavoro è stato eseguito un esempio di design di una fondazione jacket per una turbina eolica offshore.

Modelling and Uncertainty Quantification application to SA simulation codes in advanced SMR

In the framework of a global transition to a low-carbon energy mix, the interest in advanced nuclear Small Modular Reactors (SMRs) has been growing at the international level. Due to the high level of maturity reached by Severe Accident Codes for currently operating rectors, their applicability to advanced SMRs is starting to be studied. Within the present work of thesis and in the framework of a collaboration between ENEA, UNIBO and IRSN, an ASTEC code model of a generic IRIS reactor has been developed. The simulation of a DBA sequence involving the operation of all the passive safety systems of the generic IRIS has been carried out to investigate the code model capability in the prediction of the thermal-hydraulics characterizing an integral SMR adopting a passive mitigation strategy. The following simulation of 4 BDBAs sequences explores the applicability of Severe Accident Codes to advance SMRs in beyond-design and core-degradation conditions. The uncertainty affecting a code simulation can be estimated by using the method of Input Uncertainty Propagation, whose application has been realized through the RAVEN-ASTEC coupling and implementation on an HPC platform. This probabilistic methodology has been employed in a study of the uncertainty affecting the passive safety system operation in the DBA simulation of ASTEC, providing a further characterization of the thermal-hydraulics of this sequence. The application of the Uncertainty Quantification method to early core-melt phenomena has been investigated in the framework of a BEPU analysis of the ASTEC simulation of the QUENCH test-6 experiment. A possible solution to the encountered challenges has been proposed through the application of a Limit Surface search algorithm.

Propagation modelling and resource allocation in mobile radio communications

Over the past years, ray tracing (RT) models popularity has been increasing. From the nineties, RT has been used for field prediction in environment such as indoor and urban environments. Nevertheless, with the advent of new technologies, the channel model has become decidedly more dynamic and to perform RT simulations at each discrete time instant become computationally expensive. In this thesis, a new dynamic ray tracing (DRT) approach is presented in which from a single ray tracing simulation at an initial time t0, through analytical formulas we are able to track the motion of the interaction points. The benefits that this approach bring are that Doppler frequencies and channel prediction can be derived at every time instant, without recurring to multiple RT runs and therefore shortening the computation time. DRT performance was studied on two case studies and the results shows the accuracy and the computational gain that derives from this approach. Another issue that has been addressed in this thesis is the licensed band exhaustion of some frequency bands. To deal with this problem, a novel unselfish spectrum leasing scheme in cognitive radio networks (CRNs) is proposed that offers an energy-efficient solution minimizing the environmental impact of the network. In addition, a network management architecture is introduced and resource allocation is proposed as a constrained sum energy efficiency maximization problem. System simulations demonstrate an increment in the energy efficiency of the primary users’ network compared with previously proposed algorithms.

Modelling and classification with quantile-based distributions

In this work, we explore and demonstrate the potential for modeling and classification using quantile-based distributions, which are random variables defined by their quantile function. In the first part we formalize a least squares estimation framework for the class of linear quantile functions, leading to unbiased and asymptotically normal estimators. Among the distributions with a linear quantile function, we focus on the flattened generalized logistic distribution (fgld), which offers a wide range of distributional shapes. A novel naïve-Bayes classifier is proposed that utilizes the fgld estimated via least squares, and through simulations and applications, we demonstrate its competitiveness against state-of-the-art alternatives. In the second part we consider the Bayesian estimation of quantile-based distributions. We introduce a factor model with independent latent variables, which are distributed according to the fgld. Similar to the independent factor analysis model, this approach accommodates flexible factor distributions while using fewer parameters. The model is presented within a Bayesian framework, an MCMC algorithm for its estimation is developed, and its effectiveness is illustrated with data coming from the European Social Survey. The third part focuses on depth functions, which extend the concept of quantiles to multivariate data by imposing a center-outward ordering in the multivariate space. We investigate the recently introduced integrated rank-weighted (IRW) depth function, which is based on the distribution of random spherical projections of the multivariate data. This depth function proves to be computationally efficient and to increase its flexibility we propose different methods to explicitly model the projected univariate distributions. Its usefulness is shown in classification tasks: the maximum depth classifier based on the IRW depth is proven to be asymptotically optimal under certain conditions, and classifiers based on the IRW depth are shown to perform well in simulated and real data experiments.

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.

Numerical Analysis and Redesign of a High Speed Linear Cascade Wind Tunnel for Aircraft Gas Turbine Engines Testing

Linear cascade testing serves a fundamental role in the research, development, and design of turbomachines as it is a simple yet very effective way to compute the performance of a generic blade geometry. These kinds of experiments are usually carried out in specialized wind tunnel facilities. This thesis deals with the numerical characterization and subsequent partial redesign of the S-1/C Continuous High Speed Wind Tunnel of the Von Karman Institute for Fluid Dynamics. The current facility is powered by a 13-stage axial compressor that is not powerful enough to balance the energy loss experienced when testing low turning airfoils. In order to address this issue a performance assessment of the wind tunnel was performed under several flow regimes via numerical simulations. After that, a redesign proposal aimed at reducing the pressure loss was investigated. This consists of a linear cascade of turning blades to be placed downstream of the test section and designed specifically for the type of linear cascade being tested. An automatic design procedure was created taking as input parameters those measured at the outlet of the cascade. The parametrization method employed Bézier curves to produce an airfoil geometry that could be imported into a CAD software so that a cascade could be designed. The proposal was simulated via CFD analysis and proved to be effective in reducing pressure losses up to 41%. The same tool developed in this thesis could be adopted to design similar apparatuses and could also be optimized and specialized for the design of turbomachines components.

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.

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.

Development of a relationship between physical parameters of tsunami waves and tsunami intensity based on macroscopic effects and its application to the Italian tsunami database

Tsunamis are rare events. However, their impact can be devastating and it may extend to large geographical areas. For low-probability high-impact events like tsunamis, it is crucial to implement all possible actions to mitigate the risk. The tsunami hazard assessment is the result of a scientific process that integrates traditional geological methods, numerical modelling and the analysis of tsunami sources and historical records. For this reason, analysing past events and understanding how they interacted with the land is the only way to inform tsunami source and propagation models, and quantitatively test forecast models like hazard analyses. The primary objective of this thesis is to establish an explicit relationship between the macroscopic intensity, derived from historical descriptions, and the quantitative physical parameters measuring tsunami waves. This is done first by defining an approximate estimation method based on a simplified 1D physical onshore propagation model to convert the available observations into one reference physical metric. Wave height at the coast was chosen as the reference due to its stability and independence of inland effects. This method was then implemented for a set of well-known past events to build a homogeneous dataset with both macroseismic intensity and wave height. By performing an orthogonal regression, a direct and invertible empirical relationship could be established between the two parameters, accounting for their relevant uncertainties. The target relationship is extensively tested and finally applied to the Italian Tsunami Effect Database (ITED), providing a homogeneous estimation of the wave height for all existing tsunami observations in Italy. This provides the opportunity for meaningful comparison for models and simulations, as well as quantitatively testing tsunami hazard models for the Italian coasts and informing tsunami risk management initiatives.

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.

Sistemas de fachadas em perfilaria de alumínio, painel compósito em Alucobond e estruturas metálicas

A memória descritiva do estágio transcreve e revela os conhecimentos adquiridos ao longo do curso e aplicados ao longo do estágio, bem como todos aqueles obtidos e aperfeiçoados no estágio, nomeadamente no que espeita a planeamento, controlo de custos, aprovisionamento, preparação dos materiais e elaboração de autos de medição. Para um melhor aprofundamento destes conceitos, foi proposto pela empresa, o acompanhamento técnico de duas obras, contudo, ambas distintas quer ao nível de materiais e execução. Primeiramente, é feita uma pequena apresentação da empresa assim como uma descrição global das duas obras que foram propostas pela empresa, para fazer o acompanhamento técnico ao longo do estágio Apresentados os traços gerais do estágio é realizada uma pequena exposição teórica dos dois principais elementos, alumínio e aço, constituintes dos principais materiais utilizados nas duas obras em acompanhamento, indicando alguns dados sobre o seu modo de produção e caracterização física e mecânica. Nos dois capítulos seguintes faz-se uma descrição dos principais trabalhos realizados em ambas as obras. Na obra da rua Alfredo do Guisado são enunciados todas as tarefas da produção e da preparação em oficina para aplicação em obra de uma fachada ventilada em painel compósito de Alucobond. No que respeita a obra da Caetano Parts é feito o enquadramento do acompanhamento técnico em todas as tarefas desempenhadas pelas oficinas, descrevendo todos os processos envolvidos desde a preparação, aprovisionamento, tratamento e montagem dos diferentes materiais em obra. Por fim, são apresentadas algumas considerações finais do estágio desenvolvido.

3D geoelectrical monitoring to follow hydric soil behaviour during rainfall

RESUME Durant les dernières années, les méthodes électriques ont souvent été utilisées pour l'investigation des structures de subsurface. L'imagerie électrique (Electrical Resistivity Tomography, ERT) est une technique de prospection non-invasive et spatialement intégrée. La méthode ERT a subi des améliorations significatives avec le développement de nouveaux algorithmes d'inversion et le perfectionnement des techniques d'acquisition. La technologie multicanale et les ordinateurs de dernière génération permettent la collecte et le traitement de données en quelques heures. Les domaines d'application sont nombreux et divers: géologie et hydrogéologie, génie civil et géotechnique, archéologie et études environnementales. En particulier, les méthodes électriques sont souvent employées dans l'étude hydrologique de la zone vadose. Le but de ce travail est le développement d'un système de monitorage 3D automatique, non- invasif, fiable, peu coûteux, basé sur une technique multicanale et approprié pour suivre les variations de résistivité électrique dans le sous-sol lors d'événements pluvieux. En raison des limitations techniques et afin d'éviter toute perturbation physique dans la subsurface, ce dispositif de mesure emploie une installation non-conventionnelle, où toutes les électrodes de courant sont placées au bord de la zone d'étude. Le dispositif le plus approprié pour suivre les variations verticales et latérales de la résistivité électrique à partir d'une installation permanente a été choisi à l'aide de modélisations numériques. Les résultats démontrent que le dispositif pôle-dipôle offre une meilleure résolution que le dispositif pôle-pôle et plus apte à détecter les variations latérales et verticales de la résistivité électrique, et cela malgré la configuration non-conventionnelle des électrodes. Pour tester l'efficacité du système proposé, des données de terrain ont été collectées sur un site d'étude expérimental. La technique de monitorage utilisée permet de suivre le processus d'infiltration 3D pendant des événements pluvieux. Une bonne corrélation est observée entre les résultats de modélisation numérique et les données de terrain, confirmant par ailleurs que le dispositif pôle-dipôle offre une meilleure résolution que le dispositif pôle-pôle. La nouvelle technique de monitorage 3D de résistivité électrique permet de caractériser les zones d'écoulement préférentiel et de caractériser le rôle de la lithologie et de la pédologie de manière quantitative dans les processus hydrologiques responsables d'écoulement de crue. ABSTRACT During the last years, electrical methods were often used for the investigation of subsurface structures. Electrical resistivity tomography (ERT) has been reported to be a useful non-invasive and spatially integrative prospecting technique. The ERT method provides significant improvements, with the developments of new inversion algorithms, and the increasing efficiency of data collection techniques. Multichannel technology and powerful computers allow collecting and processing resistivity data within few hours. Application domains are numerous and varied: geology and hydrogeology, civil engineering and geotechnics, archaeology and environmental studies. In particular, electrical methods are commonly used in hydrological studies of the vadose zone. The aim of this study was to develop a multichannel, automatic, non-invasive, reliable and inexpensive 3D monitoring system designed to follow electrical resistivity variations in soil during rainfall. Because of technical limitations and in order to not disturb the subsurface, the proposed measurement device uses a non-conventional electrode set-up, where all the current electrodes are located near the edges of the survey grid. Using numerical modelling, the most appropriate arrays were selected to detect vertical and lateral variations of the electrical resistivity in the framework of a permanent surveying installation system. The results show that a pole-dipole array has a better resolution than a pole-pole array and can successfully follow vertical and lateral resistivity variations despite the non-conventional electrode configuration used. Field data are then collected at a test site to assess the efficiency of the proposed monitoring technique. The system allows following the 3D infiltration processes during a rainfall event. A good correlation between the results of numerical modelling and field data results can be observed since the field pole-dipole data give a better resolution image than the pole-pole data. The new device and technique makes it possible to better characterize the zones of preferential flow and to quantify the role of lithology and pedology in flood- generating hydrological processes.