Study and experimental characterization of the laser welding process for the manufacturing of electric powertrain components in the automotive industry

The PhD project that will be presented in this thesis is focused on the study and optimization of the production process for the manufacturing of electrical powertrain components in the automotive field using the laser beam welding process (LBW). The objective is to define, through experimental activities, an optimized process condition for applications in the electrical field that can be generalized, that is, which guarantees its reproducibility as the types of connections vary and which represents the basis for extending the method to future applications in e-mobility sector. The work developed along two lines of research, the convergence of which made it possible to create prototypes of battery modules based on different types of lithium-ion cells and stator windings for electric motors. On the one hand, the different welding configurations involving the production of batteries based on pouch cells and therefore the welding of aluminum and copper in dissimilar configuration were studied, while for the prismatic cells only one configuration was analyzed. On the other hand, the welding of pure copper hairpins with rectangular shape in edge joint configuration was studied for the production of stator windings. The experimental tests carried out have demonstrated the feasibility of using the LBW process for the production of electric powertrain components entirely designed and developed internally as the types of materials and welding configurations vary; the methodologies required for the characterization methods, necessary for the end-of-line tests, for the evaluation of the properties of the different joint configurations and components (battery and electric motor) were also defined with the aim of obtaining the best performance. The entire doctorate program was conducted in collaboration with Ferrari Auto S.p.A. and the direct industrial application of the issues addressed has been faced.

Study of materials and interphases for electrochemical energy storage from renewable sources

Batteries should be refined depending on their application for a future in which the sustainable energy demand increases. On the one hand, it is fundamental to improve their safety, prevent failures, increase energy density, and reduce production costs. On the other hand, new battery materials and architecture are required to satisfy the growing demand. This thesis explores different electrochemical energy storage systems and new methodologies to investigate complex and dynamic processes. Lithium-ion batteries are described in all their cell components. In these systems, this thesis investigates negative electrodes. Both the development of new sustainable materials and new in situ electrode characterization methods were explored. One strategy to achieve high-energy systems is employing lithium metal anodes. In this framework, ammonium hexafluorophosphate is demonstrated to be a suitable additive for stabilizing the interphase and preventing uncontrolled dendritic deposition. Deposition/stripping cycles, electrochemical impedance spectroscopy, in situ optical microscopy, and operando confocal Raman spectroscopy have been used to study lithium metal-electrolyte interphase in the presence of the additive. Redox Flow Batteries (RFBs) are proposed as a sustainable alternative for stationary applications. An all-copper aqueous RFB (CuRFB) has been studied in all its aspects. For the electrolyte optimization, spectro-electrochemical tests in diluted solution have been used to get information on the electrolyte’s electrochemical behaviour with different copper complexes distributions. In concentrated solutions, the effects of copper-to-ligand ratios, the concentration, and the counter-ion of the complexing agent were evaluated. Electrode thermal treatment was optimized, finding a compromise between the electrochemical performance and the carbon footprint. On the membrane side, a new method for permeability studies was designed using scanning electrochemical microscopy (SECM). The Cu(II) permeability of several membranes was tested, obtaining direct visualization of Cu(II) concentration in space. Also, two spectrophotometric approaches were designed for SoC monitoring systems for negative and positive half-cells.

Synthesis and characterization of prussian blue analogue materials for post-Li ion batteries

Energy issues have always been a subject of concern to people. During the past 30 years, rechargeable Li-ion batteries (LIBs) have been widely used in portable electronic devices and power tools because of their high energy density and efficiency among practical secondary batteries. While the unevenly distribution of Lithium sources and the increasing cost of lithium-raw material can not satisfy the requirement for further cost reduction, especially for the grid-scale energy storage. Post-lithium ion batteries as promising replacement for LIBs have attracted wide attention, owing to their high abundant resources and adequate insertion potential. Similar with Li-ion batteries, finding a suitable electrode material is the key for the research and application of the post-Li ion batteries. In our project, we focus our study on Prussian blue analogues (PBAs), with formula AxM[M’(CN)6]1-y□y•zH2O (0≤x≤2, 0ion, M and M’ are transition metal ions, □ represents the M’(CN)6 vacancy, which are archetype of metal-organic framework, with 3D frameworks which allow for a facile insertion/ extraction of ions with negligible lattice strain. By substituting the metal sites with different transition metals, we can get a series of compounds that can be used as both cathode and anode material for both Li-ion and post-Li batteries. The most commonly studied PBAs are metal haxacyanoferrate, with the carbon-sites of -CN- ligands fix connected with Fe. Here, we synthesized three different PBAs: manganese hexacynoferrate (MnHCF), zinc hexacynoferrate (ZnHCF) and titanium hexacynoferrate (TiHCF), using co-precipitation method, and their electrochemical properties were tested in both aqueous Na+, K+, Mg2+, Zn2+ and organic Li+, Na+ electrolytes. Various X-ray techniques were employed to study their electronic and structural properties of electrodes and electrochemical reaction mechanism during cycling.

Investigation of the electrical and electrochemical properties of nanocomposites from V2O5, polypyrrole, and polyaniline

In this work, an investigation of the electrical and electrochemical properties responsible for the energy storage capability of nanocomposites has been carried out. We demonstrate that, in the case of the V2O5 xerogel and the nanocomposites polypyrrole (Ppy)/V2O5 and polyaniline (PANI)/V2O5, the quadratic logistic equation (QLE) can be used to fit the inverse of the resistance values as a function of the injected charge in non-steady-state conditions. This contributes to a phenomenological understanding of the lithium ion and electron transport. The departure of the experimental curve from the fitting observed for the V2O5 xerogel can be attributed to the trapping sites formed during the lithium electroinsertion, which was observed by electrochemical impedance spectroscopy. The amount of trapping sites was obtained on the basis of the QLE. Similar values used to fit the inverse of the resistance were also used to fit the absorbance changes, which is also associated with the small polaron hopping from the V(IV) to the V(V) sites. On the other hand, there was good agreement between the experimental and the theoretical data when the profile of the inverse of the resistance as a function of the amount of inserted lithium ions of the nanocomposites Ppy/V2O5 and PANI/ V2O5 was concerned. We suggest that the presence of the conducting polymers is responsible for the different electrical profile of the V2O5 xerogel compared with those of the nanocomposites. In the latter case, interactions between the lithium ions and oxygen atoms from V2O5 are shielded, thus decreasing the trapping effect of lithium ions in the V2O5 sites. The different values of the lithium ion diffusion coefficient into these intercalation materials are in agreement with this hypothesis.

Implementing the quantum random walk

Recently, several groups have investigated quantum analogues of random walk algorithms, both on a line and on a circle. It has been found that the quantum versions have markedly different features to the classical versions. Namely, the variance on the line, and the mixing time on the circle increase quadratically faster in the quantum versions as compared to the classical versions. Here, we propose a scheme to implement the quantum random walk on a line and on a circle in an ion trap quantum computer. With current ion trap technology, the number of steps that could be experimentally implemented will be relatively small. However, we show how the enhanced features of these walks could be observed experimentally. In the limit of strong decoherence, the quantum random walk tends to the classical random walk. By measuring the degree to which the walk remains quantum, '' this algorithm could serve as an important benchmarking protocol for ion trap quantum computers.

Evolution of the surface plasmon resonance of Au:TiO2 nanocomposite thin films with annealing temperature

This paper reports on the changes in the structural and morphological features occurring in a particular type of nanocomposite thin-film system, composed of Au nanoparticles (NPs) dispersed in a host TiO2 dielectric matrix. The structural and morphological changes, promoted by in-vacuum annealing experiments of the as-deposited thin films at different temperatures (ranging from 200 to 800 C), resulted in a well-known localized surface plasmon resonance (LSPR) phenomenon, which gave rise to a set of different optical responses that can be tailored for a wide number of applications, including those for optical-based sensors. The results show that the annealing experiments enabled a gradual increase of the mean grain size of the Au NPs (from 2 to 23 nm), and changes in their distributions and separations within the dielectric matrix. For higher annealing temperatures of the as-deposited films, a broad size distribution of Au NPs was found (sizes up to 100 nm). The structural conditions necessary to produce LSPR activity were found to occur for annealing experiments above 300 C, which corresponded to the crystallization of the gold NPs, with an average size strongly dependent on the annealing temperature itself. The main factor for the promotion of LSPR was the growth of gold NPs and their redistribution throughout the host matrix. On the other hand, the host matrix started to crystallize at an annealing temperature of about 500 C, which is an important parameter to explain the shift of the LSPR peak position to longer wavelengths, i.e. a red-shift.

Residual Stress Measurement on a MEMS Structure With High-Spatial Resolution

A new approach to the local measurement of residual stress in microstructures is described in this paper. The presented technique takes advantage of the combined milling-imaging features of a focused ion beam (FIB) equipment to scale down the widely known hole drilling method. This method consists of drilling a small hole in a solid with inherent residual stresses and measuring the strains/displacements caused by the local stress release, that takes place around the hole. In the presented case, the displacements caused by the milling are determined by applying digital image correlation (DIC) techniques to high resolution micrographs taken before and after the milling process. The residual stress value is then obtained by fitting the measured displacements to the analytical solution of the displacement fields. The feasibility of this approach has been demonstrated on a micromachined silicon nitride membrane showing that this method has high potential for applications in the field of mechanical characterization of micro/nanoelectromechanical systems.

Transporte de carga em compósitos de polianilina/V2O5

In this work, composites formed from a mixture of V2O5 and polyaniline (PANI) were investigated, for applications as cathode materials for secondary lithium batteries. Electrochemical quartz crystal microbalance (EQCM) data show that charge compensation in the [PANI]0.3V2O5 nanocomposite is achieved predominantly by Li+ migration. However, the charge compensation in the [PANI]V2O5 microcomposite occurs by Li+ and ClO4- transport. Electrochemical Impedance Spectroscopy (EIS) measurements reveal several benefits of nanohybrid formation, including the achievement of shorter ionic diffusion pathways, the higher diffusion rate of the lithium ion and also the higher electronic conductivity, which are responsible for a synergetic effect of the energy storage properties.

Desenvolvimento de conjunto membrana-eletrodos para célula a combustível de metanol direto passiva

Direct methanol fuel cells (DMFCs) without external pumps or other ancillary devices for fuel and oxidant supply are known as passive DMFCs and are potential candidates to replace lithium-ion batteries in powering portable electronic devices. This paper presents the results obtained from a membrane electrode assembly (MEA) specifically designed for passive DMFCs. Appropriated electrocatalysts were prepared and the effect of their loadings was investigated. Two types of gas diffusion layers (GDL) were also tested. The influence of the methanol concentration was analyzed in each case. The best MEA performance presented a maximum power density of 11.94 mW cm-2.

Nikkelin, koboltin, lyijyn ja sinkin selektiivinen erottaminen ioninleimaustekniikalla syntetisoiduilla kelatoivilla erotusmateriaaleilla

Kelatoivat erotusmateriaalit ovat osoittautuneet lupaaviksi haitallisten metallien erottamiseksi vedestä. Puhdistettava vesiliuos sisältää vain harvoin pelkästään erotettavaksi tarkoitettuja metallikationeja, sillä useimmiten mukana on erotusmateriaalien tehokkuutta heikentäviä kationeja. Parantamalla erotusmateriaalin selektiivisyyttä voitaisiin häiritsevien ionien vaikutusta vähentää selvästi. Kandidaatintyön tavoitteena oli tutkia ioninleimaustekniikan avulla syntetisoitujen kelatoivien erotusmateriaalien selektiivisyyttä nikkelille, koboltille, lyijylle ja sinkille. Käyttämällä esimerkiksi nikkelitemplaattia materiaalin synteesivaiheessa materiaalin nikkeliselektiivisyys kasvaa verrattuna perinteiseen synteesitekniikkaan. Tässä työssä tutkittiin erotusmateriaaleja, joissa oli käytetty nikkeli- tai lyijytemplaattia, vertaamalla niitä ilman templaattia syntetisoituihin materiaaleihin. Lisäksi erotustehokkuutta verrattiin kaupalliseen erotusmateriaaliin häiritsevien magnesium- ja kalsiumionien tapauksessa. Lyijyn havaittiin sitoutuvan tehokkaimmin kaikkiin syntetisoituihin materiaaleihin riippumatta nikkelitemplaatin käyttämisestä. Kinetiikkakokeet osoittivat lyijyn sitoutumisnopeudenkin olevan vertailtavista metalleista suurin. Kaikki kokeet suoritettiin huoneenlämpötilassa liuoksen pH-arvon ollessa 7,5. Nikkelitemplaatin käyttö lisäsi materiaalin selektiivisyyttä nikkelille verrattuna templaatittomaan muuten identtiseen materiaaliin. Kuitenkin materiaalien lyijyselektiivisyys oli huomattavasti nikkeliselektiivisyyttä suurempi. Lyijytemplaatin käyttö ei lisännyt lyijyselektiivisyyttä, mutta materiaalin nikkeliselektiivisyys parantui. Materiaaliin sitoutuneet nikkeli-, koboltti- ja sinkkipitoisuudet jäivät huomattavasti vähäisemmiksi verrattuna kaupalliseen materiaaliin. Magnesiumin ja kalsiumin tarttumista syntetisoituihin materiaaleihin tutkittiin myös ja tulosten mukaan IIPD2:een ja IIPD2-Methoxiin sitoutui erittäin vähän magnesiumia ja kalsiumia verrattuna kaupalliseen materiaaliin, jonka kalsiumkapasiteetti oli erityisen suuri. Kyseiset materiaalit soveltuvat tulosten perusteella myös häiritseviä ioneja sisältävien liuosten puhdistamiseen. Näin ollen valittujen kahden materiaalin jatkotutkimuksella olisi mahdollista parantaa nikkelikapasiteettia ja -selektiivisyyttä.

2-(aminometyyli)pyridiini ligandin kompleksoituminen nikkelin kanssa eri liuottimissa

Kandidaatintyön tavoitteena oli tutkia 2-(aminometyyli)pyridiini ligandin kompleksoitumista nikkeli(II) ionin kanssa vesiliuoksissa ja eri orgaanisissa liuotinseoksissa. Työ tehtiin osana laajempaa tutkimusta, jossa pyritään määrittämään nikkelille spesifisiä erotusmateriaaleja ion imprinting tekniikkaa hyväksikäyttäen. Koesarjat sekä näihin liittyvä mittaukset suoritettiin kaikki huoneen lämmössä sekä normaalissa ilman paineessa. Koesarjojen liuosfaaseista määritettiin UV/Vis spektrofotometrisesti spektrit, joiden perusteella piirrettiin Job Plot kuvaajat. Kuvaajien havaittiin vastaavan aikaisemmissa tutkimuksissa määritettyjä kuvaajia sekä matemaattisesti laskettuja huippuarvoja. Saostuneiden kiintoaineiden koostumukset määritettiin XRD ja IR mittauksilla. Tuloksien perusteella todettiin 1:2 kompleksin saostuvan lähes poikkeuksetta kaikista saostuneista näytteistä. Mittaustuloksista johtopäätöksinä voidaan todeta liuotinseoksien ja veden määrän vaikuttavan muodostuneen kompleksin kiderakenteeseen, mutta ei saostuvaan kompleksiin.

Signal transduction induced in Trypanosoma cruzi metacyclic trypomastigotes during the invasion of mammalian cells

Penetration of Trypanosoma cruzi into mammalian cells depends on the activation of the parasite's protein tyrosine kinase and on the increase in cytosolic Ca2+ concentration. We used metacyclic trypomastigotes, the T. cruzi developmental forms that initiate infection in mammalian hosts, to investigate the association of these two events and to identify the various components of the parasite signal transduction pathway involved in host cell invasion. We have found that i) both the protein tyrosine kinase activation, as measured by phosphorylation of a 175-kDa protein (p175), and Ca2+ mobilization were induced in the metacyclic forms by the HeLa cell extract but not by the extract of T. cruzi-resistant K562 cells; ii) treatment of parasites with the tyrosine kinase inhibitor genistein blocked both p175 phosphorylation and the increase in cytosolic Ca2+ concentration; iii) the recombinant protein J18, which contains the full-length sequence of gp82, a metacyclic stage surface glycoprotein involved in target cell invasion, interfered with tyrosine kinase and Ca2+ responses, whereas the monoclonal antibody 3F6 directed at gp82 induced parasite p175 phosphorylation and Ca2+ mobilization; iv) treatment of metacyclic forms with phospholipase C inhibitor U73122 blocked Ca2+ signaling and impaired the ability of the parasites to enter HeLa cells, and v) drugs such as heparin, a competitive IP3-receptor blocker, caffeine, which affects Ca2+ release from IP3-sensitive stores, in addition to thapsigargin, which depletes intracellular Ca2+ compartments and lithium ion, reduced the parasite infectivity. Taken together, these data suggest that protein tyrosine kinase, phospholipase C and IP3 are involved in the signaling cascade that is initiated on the parasite cell surface by gp82 and leads to Ca2+ mobilization required for target cell invasion.

Litiumin erotus väkevistä kloridiliuoksista ioninvaihdolla

Litiumioniakkujen kehityksen myötä litiumin tarve ja kysyntä ovat kasvaneet viime vuodet tasaisesti noin 10 % vuosivauhdilla. Kasvun on myös ennustettu jatkuvan samanlaisena tulevaisuudessa, jonka takia erilaiset litiumin erotusprosessit ovat nousseet tutkimuksen kohteeksi. Tärkeimmät litiumlähteet sijaitsevat suola-aavikoilla ja -järvillä, joihin litiumia on kerääntynyt suuria määriä maanpinnan läheisyyteen. Litiumia erotetaan suolatasangoilla aikaa vievissä haihdutus- ja saostusvaiheissa. Suolaliuokset sisältävät litiumin lisäksi muita metalleja, kuten magnesiumia, kalsiumia ja natriumia, joista etenkin magnesium häiritsee litiumin erotusta. Aikaisemmissa tutkimuksissa ei ole löydetty litiumille riittävän selektiivistä ioninvaihtohartsia. Tehdyissä tutkimuksissa muut metallit on usein erotettu selektiivisesti ennen litiumia ja litium on erotettu lopuksi. Litiumin erotusta voitaisiin parantaa, mikäli se onnistuisi selektiivisesti suoraan suolaliuoksesta. Tässä työssä tutkittiin litiumin selektiivistä erotusta magnesium- ja kalsiumpitoisesta väkevästä kloridiliuoksesta ioninvaihtohartseilla sekä molekyyliseulalla. Käytetyt neljä ioninvaihtohartsia olivat kaupallisia Puroliten hartseja: MN200, S940, CT151 ja A170. Molekyyliseula oli Sigman huokoskoon 4 Å zeoliittia. Kromatografisilla kolonnikokeilla saadut näytteet analysoitiin ICP-AES:lla. Tulosten perusteella ei yksikään tutkituista hartseista ja molekyyliseulasta ollut selektiivinen litiumille.

Determination of the thermal parameters of high-power batteries by local heat

A new approach to the determination of the thermal parameters of high-power batteries is introduced here. Application of local heat flux measurement with a gradient heat flux sensor (GHFS) allows determination of the cell thermal parameters in di_erent surface points of the cell. The suggested methodology is not cell destructive as it does not require deep discharge of the cell or application of any charge/discharge cycles during measurements of the thermal parameters of the cell. The complete procedure is demonstrated on a high-power Li-ion pouch cell, and it is verified on a sample with well-known thermal parameters. A comparison of the experimental results with conventional thermal characterization methods shows an acceptably low error. The dependence of the cell thermal parameters on state of charge (SoC) and measurement points on the surface was studied by the proposed measurement approach.

Synthèse du LiXFePO4 par voie fondue et l’étude de la couche de carbone sur LiFePO4

Le LiFePO4 est un matériau prometteur pour les cathodes des batteries au lithium. Il possède une bonne stabilité à haute température et les précurseurs utilisés pour la synthèse sont peu couteux. Malheureusement, sa faible conductivité nuit aux performances électrochimiques. Le fait de diminuer la taille des particules ou d’enrober les particules d’une couche de carbone permet d’augmenter la conductivité. Nous avons utilisé une nouvelle méthode appelée « synthèse par voie fondue » pour synthétiser le LiFePO4. Cette synthèse donne des gros cristaux et aucune impureté n’est détectée par analyse Rayon-X. En revanche, la synthèse de LiXFePO4 donne un mélange de LiFePO4 pur et d’impureté à base de lithium ou de fer selon l’excès de fer ou de lithium utilisé. La taille des particules de LiFePO4 est réduite à l’aide d’un broyeur planétaire et plusieurs paramètres de broyage sont étudiés. Une couche de carbone est ensuite déposée sur la surface des particules broyées par un traitement thermique sur le LiFePO4 avec du -lactose. L’influence de plusieurs paramètres comme la température du traitement thermique ou la durée du chauffage sont étudiés. Ces expériences sont réalisées avec un appareil d’analyse thermogravimétrique (ATG) qui donne la quantité de chaleur ainsi que la variation de masse durant le chauffage de l’échantillon. Ce nouveau chauffage pour la couche de carbone donne des échantillons dont les performances électrochimiques sont similaires à celles obtenues précédemment avec la méthode de chauffage pour la couche de carbone utilisant le four tubulaire.