Analisi e simulazione FEM del processo di infusione sottovuoto "VARI" di una passerella nautica

Tesi svolta presso l'azienda “Riba composites S.r.l.” con lo scopo di riprogettare una passerella nautica utilizzata in imbarcazioni a vela da competizione, attualmente realizzata mediante formatura in autoclave di tessuti pre-impregnati, per il processo produttivo di Vacuum Assisted Resin Injection (VARI). La formatura in autoclave di tessuti pre-­impregnati è una delle tecnologie più onerose, tra i vari processi produttivi nel settore dei materiali compositi, ma assicura proprietà meccaniche e livelli estetici superlativi. L’obiettivo della Riba Composites è ridurre i costi di produzione per offrire un prodotto dalle proprietà analoghe a un prezzo più competitivo. Nella fase di riprogettazione ci siamo affidati a un software di calcolo agli elementi finiti che simula il processo del VARI, l’applicativo PAM-­RTM, del gruppo ESI. Al fine di ottenere una simulazione quanto più precisa possibile del processo, abbiamo realizzato molteplici prove sperimentali per ricavare i valori di compressibilità e permeabilità dei rinforzi da inserire nel software FEM.

Studio di metodi di preparazione e caratterizzazione di nanostrutture per la funzionalizzazione di materiali ceramici

This thesis was carried out in the context of a co-tutoring program between Centro Ceramico Bologna (Italy) and Instituto di Tecnologia Ceramica, Castellón de la Plana (Spain). The subject of the thesis is the synthesis of silver nanoparticles and at their likely decorative application in the productive process of porcelain ceramic tiles. Silver nanoparticles were chosen as a case study, because metal nanoparticles are thermally stable, and they have non-linear optical properties when nano-structured, and therefore they develop saturated colours. The nanoparticles were synthesized by chemical reduction in aqueous solution, a method chosen because of its reduced working steps and energy costs. Besides such a synthesis method uses non-expensive and non-toxic raw material. By adopting this synthesis technique, it was also possible to control the dimension and the final shape of the nanoparticles. Several syntheses were carried out during the research work, modifying the molecular weight of the reducing agent and/or the firing temperature, in order to evaluate the influence such parameters have on the Ag-nanoparticles formation. The syntheses were monitored with the use of UV-Vis spectroscopy and the average dimension as well as the morphology of the nanoparticles was analysed by SEM. From the spectroscopic data obtained from each synthesis, a kinetic study was completed, relating the progress of the reaction to the two variables (ie temperature and molecular weight of the reducing agent). The aim was finding equations that allow the establishing of a relationship between the operating conditions during the synthesis and the characteristics of the final product. The next step was finding the best method of synthesis for the decorative application. For such a purpose the amount of nanoparticles, their average particle size, the shape and the agglomeration are considered. An aqueous suspension containing the nanoparticles is then sprayed over the fired ceramic tiles and they are subsequently thermally treated in conditions similar to the industrial one. The colorimetric parameters of the obtained ceramic tiles were studied and the method proved successful, giving the ceramic tiles stable and intense colours.

Campionamento e determinazione di sostanze rilevanti per la valutazione della capacità ossidante dell’atmosfera e studio del loro effetto sui materiali ceramici

Carbonyl compounds are very important volatil organic compounds receiving increasing attention due to their critical role in tropospheric organic chemistry and to their effects on human health. They are first photo-oxidation stage of almost all organic compounds and originators of free radicals (OH, O3...). Therfore, continuous determination of their atmospheric concentrations is essential. Currently, field measurements are very limited mainly because of the analytical challenges posed by trace concentrations and interferences arising from atmospheric co-pollutants. Additionally, hydroxyl radical (OH) plays a central role in atmospheric chemistry processes. The measurement of atmospheric OH concentrations is essential for the comprehension of atmospheric chemical and photochemical processes. In this context, objectives of this work were: To perform a continuous survey of atmospheric concentrations of carbonyl compounds on different sites around the area of Bologna. For this purpose, an automatic instrument for the continuous measurement (one hour of time resolution) was developed and used. Additionally, the development of a complete and original analytical method was realised. To develop an original OH generation system in order to evaluate the effect of OH and the reactivity of solid and/or liquid materials of interest. This included the validation of an analytical method for the quantification of OH concentrations generated. Effect of OH on ceramic materials and reactivity of snow surface samples, involved as sink of OH in atmospheric chemistry, were evaluated.

Produzione di compositi a matrice di alluminio con rinforzo particellare nanometrico

Le leghe di alluminio da fonderia rivestono un ruolo fondamentale in ambito industriale e in particolare il settore dei trasporti ha notevolmente incrementato il loro impiego per la realizzazione di componenti strutturali. Al fine di aumentare ulteriormente la resistenza specifica, tali leghe possono essere impiegate come matrici per lo sviluppo di compositi (Metal Matrix Composites, MMCs), le cui fasi di rinforzo possono avere diversa composizione, forma e dimensione. In particolare, nel caso di rinforzo particellare, più le particelle sono piccole e finemente disperse nella matrice, più elevato può essere l’incremento delle prestazioni meccaniche. In quest’ottica, la ricerca ha portato allo sviluppo dapprima di compositi caratterizzati da un rinforzo micrometrico e, in anni recenti, si sta concentrando sul rinforzo nanometrico (Metal Matrix Nano Composites, MMNCs). I nano-compositi possono essere ottenuti attraverso metodologie differenti: tecniche in situ, in cui il rinforzo viene generato all’interno della matrice attraverso opportune reazioni chimiche, e tecniche ex situ, in cui i dispersoidi vengono inseriti nella matrice fusa, una volta già formati. Sebbene l’incremento prestazionale ottenibile da tali materiali sia stato dimostrato, è necessario far fronte ad alcune problematiche connesse a ciascuna tecnologia produttiva quali, ad esempio, il controllo dei parametri di processo, per quanto riguarda le tecniche in situ, e l’ottenimento di una efficace dispersione delle nano-particelle all’interno della matrice, nel caso delle metodologie ex-situ. Lo scopo della presente attività di tesi è lo studio di fattibilità, basato anche su un’ampia indagine bibliografica, e l’implementazione di metodologie produttive, su scala di laboratorio, volte allo sviluppo di MMNCs a matrice in lega di alluminio (A356, Al-Si-Mg). L’interesse è stato posto in primo luogo sul processo in situ di gas bubbling, mirato all’ottenimento di rinforzo d’allumina, indotto dalla reazione tra matrice metallica e gas ossidante (in questo caso aria secca industriale). In secondo luogo, dal punto di vista delle tecniche ex situ, è stato approfondito l’aspetto della dispersione delle particelle di rinforzo nel fuso, prestando particolare attenzione alla tecnica di trattamento ultrasonico del metallo.

Costruzione di un sistema per l'alimentazione dei materiali alla produzione: il caso Bosch Rexroth Oil Control S.p.A.

Il seguente elaborato è il risultato di uno stage di sei mesi, svolto presso l’azienda Bosch Rexroth Oil Control S.p.A.. L’ente presso cui è stato svolto il tirocinio è l’Industrial Engineering. In particolare è stata compiuta un’analisi dei flussi delle cartucce meccaniche, una famiglia di valvole oleodinamiche. Il lavoro si è sviluppato in tre fasi: nella prima è stata fatta un’analisi dei dati di giacenza, tempi e cicli di lavoro delle cartucce; nella seconda fase si è proposta l’introduzione di un nuovo sistema di picking gestito con supermarket a kanban; nell’ultima fase si è valutata la convenienza dai punti di vista tecnico ed economico del progetto.

I materiali ceramici trasparenti: preparazione, caratterizzazione e correlazione microstruttura-proprietà

This thesis focuses on the ceramic process for the production of optical grade transparent materials to be used as laser hosts. In order to be transparent a ceramic material must exhibit a very low concentration of defects. Defects are mainly represented by secondary or grain boundary phases and by residual pores. The strict control of the stoichiometry is mandatory to avoid the formation of secondary phases, whereas residual pores need to be below 150 ppm. In order to fulfill these requirements specific experimental conditions must be combined together. In addition powders need to be nanometric or at least sub-micrometric and extremely pure. On the other hand, nanometric powders aggregate easily and this leads to a poor, not homogeneous packing during shaping by pressing and to the formation of residual pores during sintering. Very fine powders are also difficult to handle and tend to absorb water on the surface. Finally, the powder manipulation (weighting operations, solvent removal, spray drying, shaping, etc), easily introduces impurities. All these features must be fully controlled in order to avoid the formation of defects that work as scattering sources thus decreasing the transparency of the material. The important role played by the processing on the transparency of ceramic materials is often underestimated. In the literature a high level of transparency has been reported by many authors but the description of the experimental process, in particular of the powder treatment and shaping, is seldom extensively described and important information that are necessary to reproduce the described results are often missing. The main goal of the present study therefore is to give additional information on the way the experimental features affect the microstructural evolution of YAG-based ceramics and thus the final properties, in particular transparency. Commercial powders are used to prepare YAG materials doped with Nd or Yb by reactive sintering under high vacuum. These dopants have been selected as the more appropriate for high energy and high peak power lasers. As far as it concerns the powder treatment, the thesis focuses on the influence of the solvent removal technique (rotavapor versus spray drying of suspensions in ethanol), the ball milling duration and speed, suspension concentration, solvent ratio, type and amount of dispersant. The influence of the powder type and process on the powder packing as well as the pressure conditions during shaping by pressing are also described. Finally calcination, sintering under high vacuum and in clean atmosphere, and post sintering cycles are studied and related to the final microstructure analyzed by SEM-EDS and HR-TEM, and to the optical and laser properties.

Studio di catalisi termoattivate per compositi poliuretanici

One of the key processing parameters in thermoset composites manufacturing is to have an optimum balance between open time and cure time. Long open times followed with a fast cure profile (also referred as snap cure or “hockey stick” shaped profiles) are required on applications like Pultrusion, Filament Winding, Resin Transfer Molding (RTM) and Infusion. In this work, several factors affecting the reactivity of a base line polyurethane formulation were studied. The addition of different components such as internal mold release agents, cross-linker, polyols having different molecular structure and isocyanates having different functionality were studied. A literature search was conducted to identify the main catalyst packages existing in the market. The reactivity of catalyst based on tertiary amines, orgamometallic salts, and co-catalyst of amine-organometallic complexes was characterized. Addition of quelants agents such as thioglycerol and acetyl acetone to delay the catalyst activity were also considered. As a consequence of this work a vast reactivity map was generated. This should guide the formulation designer in future product generations for the further development of the mentioned applications. Recommendations on measurements systems and further areas of exploration are also given.

Caratterizzazione meccanica multiscala di materiali rocciosi strutturalmente complessi

The research work was aimed at studying, with a deterministic approach, the relationships between the rock’s texture and its mechanical properties determined at the laboratory scale. The experimentation was performed on a monomineralic crystalline rock, varying in texture, i.e. grains shape. Multi-scale analysis has been adopted to determine the elasto-mechanical properties of the crystals composing the rock and its strength and deformability at the macro-scale. This let us to understand how the structural variability of the investigated rock affects its macromechanical behaviour. Investigations have been performed on three different scales: nano-scale (order of nm), micro-scale (tens of m) and macro-scale (cm). Innovative techniques for rock mechanics, i.e. Depth Sensing Indentation (DSI), have been applied, in order to determine the elasto-mechanical properties of the calcite grains. These techniques have also allowed to study the influence of grain boundaries on the mechanical response of calcite grains by varying the indents’ sizes and to quantify the effect of the applied load on the hardness and elastic modulus of the grain (indentation size effect, ISE). The secondary effects of static indentation Berkovich, Vickers and Knoop were analyzed by SEM, and some considerations on the rock’s brittle behaviour and the effect of microcracks can be made.