Energy and raw material consumption analysis of powder bed fusion: case study: CNC machining and laser additive manufacturing

Laser additive manufacturing (LAM), known also as 3D printing, is a powder bed fusion (PBF) type of additive manufacturing (AM) technology used to manufacture metal parts layer by layer by assist of laser beam. The development of the technology from building just prototype parts to functional parts is due to design flexibility. And also possibility to manufacture tailored and optimised components in terms of performance and strength to weight ratio of final parts. The study of energy and raw material consumption in LAM is essential as it might facilitate the adoption and usage of the technique in manufacturing industries. The objective this thesis was find the impact of LAM on environmental and economic aspects and to conduct life cycle inventory of CNC machining and LAM in terms of energy and raw material consumption at production phases. Literature overview in this thesis include sustainability issues in manufacturing industries with focus on environmental and economic aspects. Also life cycle assessment and its applicability in manufacturing industry were studied. UPLCI-CO2PE! Initiative was identified as mostly applied exiting methodology to conduct LCI analysis in discrete manufacturing process like LAM. Many of the reviewed literature had focused to PBF of polymeric material and only few had considered metallic materials. The studies that had included metallic materials had only measured input and output energy or materials of the process and compared to different AM systems without comparing to any competitive process. Neither did any include effect of process variation when building metallic parts with LAM. Experimental testing were carried out to make dissimilar samples with CNC machining and LAM in this thesis. Test samples were designed to include part complexity and weight reductions. PUMA 2500Y lathe machine was used in the CNC machining whereas a modified research machine representing EOSINT M-series was used for the LAM. The raw material used for making the test pieces were stainless steel 316L bar (CNC machined parts) and stainless steel 316L powder (LAM built parts). An analysis of power, time, and the energy consumed in each of the manufacturing processes on production phase showed that LAM utilises more energy than CNC machining. The high energy consumption was as result of duration of production. Energy consumption profiles in CNC machining showed fluctuations with high and low power ranges. LAM energy usage within specific mode (standby, heating, process, sawing) remained relatively constant through the production. CNC machining was limited in terms of manufacturing freedom as it was not possible to manufacture all the designed sample by machining. And the one which was possible was aided with large amount of material removed as waste. Planning phase in LAM was shorter than in CNC machining as the latter required many preparation steps. Specific energy consumption (SEC) were estimated in LAM based on the practical results and assumed platform utilisation. The estimated platform utilisation showed SEC could reduce when more parts were placed in one build than it was in with the empirical results in this thesis (six parts).

Possibility Of Controlling The Atmosphere Inside A Package Using Microperforation

This work focuses on the study of the determination on the possibilities of controlling the required moisture within the inside of film sealed packages. The task is based on the challenges faced by fresh food producers in actualizing a longer product shelf-life coupled with the growing complex desires coming from consumers in the aspect of quality. One way to realize this is by proper evaluation on the use of the flexible plastic films through permeation measurements on the required amount of moisture penetrating through the plastic film with the application of microperforation. A packaging material requires proper interaction on moisture transmission, between the product and the outside environment. The plastic film material that stands between, fresh fruits, vegetables and the outside environment could have appropriate respiration rates through possible micro holes. This work simulates similar process with the aid of water vapor transmission rate (WVTR) experiment using anhydrous CaCl2 as the desiccant, in studying the WVTR values of various perforated film materials at different conditions of storage (standard, fridge, and tropical conditions). However, the results showed absorption rates of water vapor at various conditions in grams of H2O/m2/24h.

Optical spectroscopy of organic material based on C60

The structure and optical properties of thin films based on C60 materials are studied. Reproducible vacuum method of thin fullerene films production with Cd impurity on Si, glass and mica surfaces is developed. Surface morphology of the films are investigated by AFM and SEM methods. The ab initio quantum - chemical calculations of the geometry, total energy and excited energy states of complex fullerene- cadmium telluride supramolecules are performed. Photoluminescence spectra of composite thin films based on C60 before and after X-ray irradiation were measured. The intensity of additional peaks is defined as the charge composition due to the type of substrate. These results are interpreted as an appearance of the dipole-allowed transitions in the fullerene excited singlet states spectrum cause of an interference with cadmium telluride. X-ray irradiated films were investigated, and additional peaks in photoluminescence spectra were detected. These peaks appear as a result of molecular complexes formation from C60CdTe mixture and dimerization of the films. Density functional B3LYP quantum-chemical calculations for C60CdTe, molecular complexes, (C60)2 and C120O dimers were performed to elucidate some experimental results.

Yhdyskuntajätteen mekaanisen erottelun erotustehokkuus

EU:n jätehierarkia asettaa jätteenkäsittelyssä materiaalien hyötykäytön energiahyötykäytön edelle. EU on asettanut korkeat tavoitteet jätteenkierrätykseen, 50 painoprosenttia kotitalousjätteestä on ohjattava kierrätykseen vuoteen 2020 mennessä. Suomessa kaatopaikoista on pyritty eroon lisäämällä jätteenpolttokapasiteettia. Jätteiden hyödyntämisen osalta tilanne Suomessa on hyvä, mutta kierrätystavoitteiden täyttyminen nykyisillä toimilla vaikuttaa epätodennäköiseltä. Tässä työssä selvitetään mitä mekaanisia jätteen erottelumenetelmiä maailmalla on käytössä ja kuinka tehokkaita ne ovat. Työn tavoitteena on tutkia voitaisiinko kierrätystä Suomessa tehostaa yhdyskuntajätteen mekaanisella käsittelyllä. Kirjallisuusselvityksen lisäksi työssä on simuloitu mekaanisia erotteluketjuja ja verrattu niillä saatuja tuloksia Suomen syntypaikkalajittelun tasoon. Tämän tutkimuksen perusteella, mikään yksittäinen mekaaninen erottelumenetelmä ei riittävän tehokas erottelemaan kierrätettäviä materiaaleja yhdyskuntajätteestä. Mekaanisia erottelumenetelmiä tulee yhdistää lajittelulinjastoiksi, joiden optimoiminen on monen tekijän summa. Lajittelulinjaston suunnitteluun vaikuttavat muun muassa lähtömateriaalin laatu ja lopputuotteiden käyttötarkoitukset. Yhdyskuntajätteen sisältämä biojäte likaa herkästi muut jätteet ja vaikeuttaa mekaanisesti eroteltujen jätejakeiden uudelleenkäyttöä. Biojätteen poistaminen muiden jätteiden joukosta olisi ensiarvoisen tärkeää mekaanisen erotuksen tehokkuuden kannalta. Mekaaniset erotteluketjut poistavat tehokkaasti biojätettä ja metalleja, mutta lasin ja kuitujen osalta erotusketjujen tehokkuudet jäävät alhaisiksi. Muovien osalta mekaaninen erottelu voi parhaimmillaan ollaan erittäin tehokasta, toisaalta vaatimukset lähtömateriaalin laadulle ovat suuret. Muovien osalta syntypaikkalajittelun ja mekaanisen erottelun yhtäaikainen tehostaminen voisi tarjota ratkaisun kierrätysasteen nostamiseen.

Improving the fire retardancy of extruded/coextruded wood-plastic composites

The main objective of this thesis is to study the impact of different mineral fillers and fire retardants on the reaction-to-fire properties of extruded/coextruded wood-plastic composites (WPCs). The impact of additives on the flammability properties of WPCs is studied by cone calorimetry. The studied properties are ignition time, peak heat release rate, total heat release, total smoke production, and mass loss rate. The effects of mineral fillers and fire retardants were found to vary with the type of additive, the type of additive combinations, the amount of additives, as well as the production method of the WPCs. The study shows that talc can be used to improve the properties of extruded WPCs. Especially ignition time, peak heat release rate and mass loss rate were found to be improved significantly by talc. The most significant improvement in the fire retardancy of coextruded WPCs was achieved in combinations of natural graphite and melamine. Ignition time, peak heat release rate and total smoke production were improved essentially. High increase in smoke production was found in samples where the amount of ammonium polyphosphate was 10% or higher. Coextrusion as a structural modification was found as a promising way to improve the flammability properties of composite materials in a cost-effective way.

Estudo das características de adsorção de água e da estabilidade das microcápsulas de óleo essencial de laranja na seleção de material de parede

Este trabalho consistiu no estudo e comparação das características de adsorção de água de três amostras de microcápsulas de óleo essencial de laranja, obtidas pela secagem por atomização de três diferentes emulsões preparadas pela adição de óleo essencial de laranja (oel), a uma solução aquosa de material de parede (mp) constituída de capsul (5,0, 0,0 e 10,0%), goma arábica (5,0, 10,0 e 0,0%) sendo constante para as três emulsões a maltodextrina (36,0%), água (44,0%) e óleo essencial (10,0%). A microencapsulação foi realizada a 220 e 110° C de ar de entrada e saída do secador usando um atomizador rotativo a 20.000rpm. Com base à determinação das isotermas de adsorção de água a 30, 40 e 50° C e usando o modelo de GAB para ajustar os pontos experimentais foram avaliadas as características das isotermas, a estabilidade e área superficial de adsorção de água das diferentes amostras de microcápsulas obtidas. Os resultados indicaram ser importante o estudo das características de adsorção de água para estimar a estabilidade das microcápsulas de oel e a comparação destas mostrou que as microcápsulas obtidas pela secagem por atomização da emulsão preparada com 5,0% de capsul e 5,0% de goma arábica apresentaram o melhor resultado.

Microencapsulação de óleo essencial de laranja: seleção de material de parede

No presente trabalho se procedeu à comparação de agentes microencapsulantes, material de parede (mp), na microencapsulação de óleo essencial de laranja (material ativo) através da secagem por atomização. Foram preparadas três amostras de emulsões pela adição de óleo essencial de laranja a uma solução aquosa do mp composta de capsul (5,0, 0,0 e 10,0%), goma arábica (5,0, 10,0 e 0,0%) sendo constante para as três amostras maltodextrina (36,0%), água (44,0%) e óleo essencial (10,0%). Foram avaliadas as curvas de secagem das emulsões frente à retenção do óleo essencial de laranja e a tendência de formação de dobras superficiais das partículas e verificou-se a hipótese "menor a tendência de formação de dobras na superfície das microcápsulas maior a retenção de material ativo". A microencapsulação foi obtida pela secagem por atomização, com temperaturas de 220ºC e 110ºC do ar de entrada e de saída da câmara de secagem, respectivamente, e com atomizador rotativo (20.000rpm). A comparação das microcápsulas obtidas a partir das três amostras de emulsões mostrou que aquela preparada com 10,0% de capsul e 0,0% de goma arábica apresentou o maior resultado. O período de taxa constante de secagem desta mistura é curto e com maior retenção de umidade após a secagem. As microcápsulas obtidas apresentaram maior retenção de óleo essencial e dobras superficiais menos pronunciadas decorrentes do menor entumescimento das gotículas durante a secagem.