| 1. |
- Steffenburg-Nordenström, Joachim, 1962-
(författare)
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Process chain simulation of forming, welding and heat treatment of Alloy 718
- 2017
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Manufacturing of aero engine components requires attention to residual stress and final shape of the product in order to meet high quality product standards.This sets very high demands on involved manufacturing steps to meet design requirements. Simulation of manufacturing processes can therefore be animportant tool to contribute to quality assurance.The focus in this work is on simulation of a manufacturing process chain comprising of sheet metal forming, welding and a stress relief heat treatment.Simulation of sheet metal forming can be used to design a forming tool design that accounts for the material behaviour, e.g. spring back, and avoid problems such as wrinkling, thinning and cracking. Moreover, the simulation can also show how the material is stretched and work hardened. The residual stresses after forming may be of local character or global depending on the shape that is formed. However, the heat affected zone due to welding is located near the weld.The weld also causes large residual stresses with the major component along the weld. It is found that the magnitude of the residual stresses after welding is affected by remaining stresses from the previous sheet metal forming. The final stress relieve treatment will relax these residual stresses caused by e.g. forming and welding. However, this causes additional deformations.The main focus of this study is on how a manufacturing process step affects the subsequent step when manufacturing a component of the nickel-based super alloy 718. The chosen route and geometry is a simplified leading edge of an exhaust case guide vane. The simulations were validated versus experiments. The computed deformations were compared with measurements after each manufacturing step. The overall agreement between experiments and measurement was good. However, not sufficiently accurate considering the required tolerance of the component. It was found from simulations that the residual stresses after each process affects the subsequent step. After a complete manufacturing process chain which ends with a stress relief heat treatment the residual stresses were not negligible. VIII Special experiments were performed for studying the stress relief in order to understand how the stresses evolve through the heat treatment cycle during relaxation. It was found that the stresses were reduced already during the beginning of the heating up sequence due to decreasing Young´s modulus and yield stress with increasing temperature. Relaxation due to creep starts when a certain temperature was reached which gave a permanent stress relief.
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| 2. |
- Andersson, Oscar
(författare)
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Process planning of resistance spot welding
- 2013
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Manufacturing engineering in general has experienced an increased demand of process planning in order to optimize processes to reduce costs, environmental impact and increase time efficiency. Resistance spot welding (RSW) is a common and large-scale joining method in several manufacturing industries indicating significant potentials of efficient process planning.The goal of this thesis is to establish new knowledge for updated and improved process planning of RSW in industrial applications. The goal is expressed by two research questions targeting the issues of process variations and potential of numerical methods of the RSW process. The research questions are expressed in terms of weld size, which is the main interest in RSW process planning.As any large-scale manufacturing process, RSW involves variations in results – the weld size is known to vary, both as a result of intentional dependent parameters such as process parameters and as a result of unintentional variations in welding conditions. A series of physical and numerical analysis have been performed in order to gain knowledge of such variations.The unintentional variations, which result in varying weld sizes in apparently identical conditions, were analyzed through both controlled laboratory welding and welding in industrial production environments. The results of the analysis showed the magnitude of standard deviations in both environments and the distribution of weld sizes. The analysis showed that common standard deviations in controlled laboratories and industrial production are approximately 0.3 mm and 0.9 mm, respectively and that weld sizes are distributed showed promising fit to both Normal and Weibull distributions.The intentional variations of weld sizes due to process parameters, which is the most important aspect of RSW process planning, have traditionally been analyzed through physical testing. In the present thesis two numerical methods were evaluated; regression analysis and FE simulations. For the regression analysis several models were generated and showed a standard deviation of residuals between model and physical results of 0.5 mm. For the FE simulations, material models for the RSW were generated and the simulations showed a standard deviation compared to physical testing of 0.68 mm. In conclusion, the present thesis presents results, which help quantify variations in weld sizes and present the capability of numerical methods of the RSW process.
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| 3. |
- Elm Svensson, Erik, 1976-
(författare)
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Nanomaterials for high-temperature catalytic combustion
- 2007
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Katalytisk förbränning är en lovande teknik för användning vid kraftgenerering, särskilt för gasturbiner. Genom att använda katalytisk förbränning kan man nå mycket låga emissioner av kväveoxider (NOX), kolmonoxid (CO) och oförbrända kolväten (UHC) samtidigt, vilket är svårt vid konventionell förbränning. Förutom att man erhåller låga emissioner, kan katalytisk förbränning stabilisera förbränningen och kan därmed användas för att uppnå stabil förbränning för gaser med låga värmevärden. Denna avhandling behandlar huvudsakligen högtemperaturdelen av den katalytiska förbränningskammaren. Kraven på denna del har visat sig svåra att nå. För att den katalytiska förbränningskammaren ska kunna göras till ett alternativ till den konventionella, måste katalysatorer med bättre stabilitet och aktivitet utvecklas. Målet med denna avhandling har varit att utveckla katalysatorer med högre aktivitet och stabilitet, lämpliga för högtemperaturdelen av en katalytisk förbränningskammare för förbränning av naturgas. En mikroemulsionsbaserad framställningsmetod utvecklades för att undersöka om den kunde ge katalysatorer med bättre stabilitet och aktivitet. Bärarmaterial som är kända för sin stabilitet, magnesia och hexaaluminat, framställdes med den nya metoden. Mikroemulsionsmetoden användes också för att impregnera de framställda materialen med de mer aktiva materialen perovskit (LaMnO3) och ceriumdioxid (CeO2). Det visade sig att mikroemulsionsmetoden kan användas för att framställa katalysatorer med bättre aktivitet jämfört med de konventionella framställningsmetoderna. Genom att använda mikroemulsionen för att lägga på aktiva material på bäraren erhölls också en högre aktivitet jämfört med konventionella beläggningsstekniker. Eftersom katalysatorerna ska användas under lång tid i förbräningskammaren utfördes också en åldringsstudie. Som jämförelse användes en av de mest stabila materialen som rapporterats i litteraturen: LMHA (mangan-substituerad lantan-hexaaluminat). Resultaten visade att LMHA deaktiverade mycket mer jämfört med flera av katalysatorerna innehållande ceriumdioxid på hexaaluminat som framställts med den utvecklade mikroemulsionstekniken.
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| 4. |
- Fahlström, Karl
(författare)
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Laser welding of boron steels for light-weight vehicle applications
- 2015
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Laser beam welding has gained a significant interest during the last two decades. The suitability of the process for high volume production has the possibility to give a strong advantage compared to several other welding methods. However, it is important to have the process in full control since various quality issues may otherwise occur. During laser welding of boron steels quality issues such as imperfections, changes in local and global geometry as well as strength reduction can occur. The aspects that need to be considered are strongly depending on alloy content, process parameters etc. These problems that can occur could be fatal for the construction and the lowest level of occurrence is wanted, independent of industry.The focus of this study has been to investigate the properties of laser welded boron steel. The study includes laser welding of boron alloyed steels with strengths of 1500 MPa and a recently introduced 1900 MPa grade. Focus has been to investigate weldability and the occurrence of cracks, porosity and strength reducing microstructure that can occur during laser welding, as well as distortion studies for tolerances in geometry. The results show that both conventional and 1900 MPa boron alloyed steel are suitable for laser welding.Due to the martensitic structure of welds the material tends to behave brittle. Cracking and porosity do not seem to be an issue limiting the use of these steels. For tolerances in geometry for larger structures tests has been done simulating laser welding of A-pillars and B-pillars. Measurements have been done with Vernier caliper as well as a more advanced optical method capturing the movements during the welding sequence. Results from the tests done on Ushaped beams indicates that depending on the geometry of the structure and heat input distortions can be controlled to give distortions from 1 to 8 mm, at a welding length of 700 mm. This means that important geometry points can be distorted several millimeters if the laser welding process not is controlled.
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| 5. |
- Harati, Ebrahim
(författare)
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Fatigue strength of welds in 800 MPa yield strength steels : Effects of weld toe geometry and residual stress
- 2015
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Nowadays there is a strong demand for lighter vehicles in order to increase the pay load. Through this the specific fuel consumption is decreased, the amount of greenhouse gases is lowered and the transport economy improved. One possibility to optimize the weight is to make the components from high strength steels and join them by welding. Welding is the main joining method for fabrication of a large proportion of all engineering structures. Many components experience fatigue loading during all or part of their life time and welded connections are often the prime location of fatigue failure.Fatigue fracture in welded structures often initiates at the weld toe as aconsequence of large residual stresses and changes in geometry acting as stress concentrators. The objective of this research is to increase the understanding of the factors that control fatigue life in welded components made from very high strength steels with a yield strength of more than 800 MPa. In particular the influences of the local weld toe geometry (weld toe radius and angle) and residual stress on fatigue life have been studied. Residual stresses have been varied by welding with conventional as well as Low Transformation Temperature (LTT) filler materials. The three non-destructive techniques Weld Impression Analysis (WIA), Laser Scanning Profiling (LSP) and Structured Light Projection (SLP) have been applied to evaluate the weld toe geometry.Results suggest that all three methods could be used successfully to measure the weld toe radius and angle, but the obtained data are dependent on the evaluation procedure. WIA seems to be a suitable and economical choice when the aim is just finding the radius. However, SLP is a good method to fast obtain a threedimensional image of the weld profile, which also makes it more suitable for quality control in production. It was also found that the use of LTTconsumables increased fatigue life and that residual stress has a relatively larger influence than the weld toe geometry on fatigue strength of welded parts.
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| 6. |
- Interdonato, Giovanni, 1986-
(författare)
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Signal Processing Aspects of Cell-Free Massive MIMO
- 2018
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- The fifth generation of mobile communication systems (5G) promises unprecedented levels of connectivity and quality of service (QoS) to satisfy the incessant growth in the number of mobile smart devices and the huge increase in data demand. One of the primary ways 5G network technology will be accomplished is through network densification, namely increasing the number of antennas per site and deploying smaller and smaller cells.Massive MIMO, where MIMO stands for multiple-input multiple-output, is widely expected to be a key enabler of 5G. This technology leverages an aggressive spatial multiplexing, from using a large number of transmitting/receiving antennas, to multiply the capacity of a wireless channel. A massive MIMO base station (BS) is equipped with a large number of antennas, much larger than the number of active users. The users are coherently served by all the antennas, in the same time-frequency resources but separated in the spatial domain by receiving very directive signals. By supporting such a highly spatially-focused transmission (precoding), massive MIMO provides higher spectral and energy efficiency, and reduces the inter-cell interference compared to existing mobile systems. The inter-cell interference is however becoming the major bottleneck as we densify the networks. It cannot be removed as long as we rely on a network-centric implementation, since the inter-cell interference concept is inherent to the cellular paradigm.Cell-free massive MIMO refers to a massive MIMO system where the BS antennas, herein referred to as access points (APs), are geographically spread out. The APs are connected, through a fronthaul network, to a central processing unit (CPU) which is responsible for coordinating the coherent joint transmission. Such a distributed architecture provides additional macro-diversity, and the co-processing at multiple APs entirely suppresses the inter-cell interference. Each user is surrounded by serving APs and experiences no cell boundaries. This user-centric approach, combined with the system scalability that characterizes the massive MIMO design, constitutes a paradigm shift compared to the conventional centralized and distributed wireless communication systems. On the other hand, such a distributed system requires higher capacity of back/front-haul connections, and the signal co-processing increases the signaling overhead.In this thesis, we focus on some signal processing aspects of cell-free massive MIMO. More specifically, we firstly investigate if the downlink channel estimation, via downlink pilots, brings gains to cell-free massive MIMO or the statistical channel state information (CSI) knowledge at the users is enough to reliably perform data decoding, as in conventional co-located massive MIMO. Allocating downlink pilots is costly resource-wise, thus we also propose resource saving-oriented strategies for downlink pilot assignment. Secondly, we study further fully distributed and scalable precoding schemes in order to outperform cell-free massive MIMO in its canonical form, which consists in single-antenna APs implementing conjugate beamforming (also known as maximum ratio transmission).
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| 7. |
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| 8. |
- Lindström, Per, 1967-
(författare)
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Heat Transfer Prediction of In Service Welding in a Forced Flow of Fluid
- 2005
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- An algorithm for heat transfer prediction of in-service welding operations in a forcedflow of fluid is presented. The algorithm presented is derived from Rosenthal’s 3D heatflow equation and boundary layer approximations. This was possible by the introductionof an apparent thermal conductivity kPL, which is a function of the boundary layer’s heattransfer coefficient f and the base material’s thickness . This implies that a weldcooling time ΔtT1 /T2 in a forced flow of fluid can now be calculated by an ordinaryengineering calculator and thus enabling suitable welding parameters to be determined.The magnitude of kPLf , was established by regression analysis of results from aparametric finite element analysis series of a total number of 112 numerical simulations.Furthermore, the result of the regression analysis was validated and verified by a weldingexperiment series accomplished on an in-house designed and constructed in-servicewelding rig. The principle design of the welding rig as well as its instrumentation, a PCbased Data Acquisition system, is described. In addition, a method to measure the weldmetals cooling time ΔtT1 /T2 by means of thermocouple elements is described. Finally,the algorithm presented in this study proved feasible for industrial in-service weldingoperations of fine-grained Carbon and Carbon–Manganese steels with a maximum Carbon Equivalent (IIW) (CE) of 0.32.
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| 9. |
- Rehan, Arbab
(författare)
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Microstructure and mechanical properties of a 5 wt.% Cr cold work tool steel : Influence of heat treatment procedure.
- 2017
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- The demand for Advanced High Strength Steel (AHSS) in the automotive industry is increasing day by day. It is mainly motivated by the fact that AHSS can be used as thin sheets while having high strengths. It enables weight reduction of the automobiles which consequently increases the fuel efficiency and has proven to be less harmful to the environment. It is also expected that AHSS will have even higher strength in the near future. Cold work tools steels with 5 wt.% Cr are commonly used to process AHSS. Therefore, the tool steel must meet the challenges in the future, i.e. have even higher hardness, compressive strength and toughness. One way of increasing the mechanical properties of the tool steel is by improving the heat treatment parameters. However, it is not possible without a deeper understanding of the heat treatment process. Therefore, this work presents investigations related to phase transformations occurring in a 5 wt.% Cr cold work tool steel during heat treatment. Furthermore, the influence of austenitisation and tempering temperatures on the microstructure and mechanical properties were investigated. The studies revealed that a higher austenitisation temperature can be used to achieve a higher hardness, good compressive strength and adequate toughnessof the steel. However, too high austenitisation temperature may result inexcessive coarsening of prior austenite grains which reduced the impact toughness. It was also found that retained austenite can transform during tempering by two different mechanisms. Firstly, when tempering at 525°C, carbides precipitate in retained austenite lowering its stability and permitting a transformation to marten site on cooling. Secondly, when tempering at 600°Cfor extended holding time retained austenite isothermally transforms to ferrite and carbides. This occurs by precipitation of carbides in retained austenite followed by a final transformation to ferrite and carbides.These results were used to understand the standard tempering procedure of the 5 wt.% Cr cold work tool steel. Furthermore, alternative heat treatment procedures are discussed based on the important findings presented in this thesis.
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| 10. |
- Segerstark, Andreas
(författare)
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Additive Manufacturing using Alloy 718 Powder : Influence of Laser Metal Deposition Process Parameters on Microstructural Characteristics
- 2015
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Additive manufacturing (AM) is a general name used for production methodswhich have the capabilities of producing components directly from 3D computeraided design (CAD) data by adding material layer-by-layer until a final component is achieved. Included here are powder bed technologies, laminated object manufacturing and deposition technologies. The latter technology is used in this study.Laser metal deposition using powder as an additive (LMD-p) is an AM processwhich uses a multi-axis computer numerical control (CNC) machine or robot toguide the laser beam and powder nozzle over the deposition surface. Thecomponent is built by depositing adjacent beads layer by layer until thecomponent is completed. LMD-p has lately gained attention as a manufacturing method which can add features to semi-finished components or as a repair method. LMD-p introduce a low heat input compared to arc welding methods and is therefore well suited in applications where a low heat input is of an essence. For instance, in repair of sensitive parts where too much heating compromises the integrity of the part.The main part of this study has been focused on correlating the main processparameters to effects found in the material which in this project is the superalloy Alloy 718. It has been found that the most influential process parameters are the laser power, scanning speed, powder feeding rate and powder standoff distance and that these parameters has a significant effect on the dimensionalcharacteristics of the material such as height and width of a single deposit as wellas the straightness of the top surface and the penetration depth.To further understand the effects found in the material, temperaturemeasurements has been conducted using a temperature measurement methoddeveloped and evaluated in this project. This method utilizes a thin stainless steel sheet to shield the thermocouple from the laser light. This has proved to reduce the influence of the emitted laser light on the thermocouples.
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