Industrial and Materials Science

"Metal Additive Manufacturing for Early Concept Validation"
Abstract:&nbsp; The manufacture of prototypes using metal additive manufacturing (AM) has been used for many years, however, there has been little research on how to heat treat AM aluminum parts to match the properties of parts manufactured using high pressure die casting (HPDC). Prototypes made using sand casting can only reach 70% of the strength of production HPDC parts, which is not ideal for early testing. As printed, the strength of AM aluminum manufactured with powder bed fusion – laser beam (PBF-LB) is much higher than HPDC aluminum, meaning that AM parts can be heat treated to reduce their strength until it matches that of HPDC parts. This research investigated how the heat treatment of PBF-LB processed Al10SiMg alloy affects its hardness, yield strength, ductility, and microstructure, as well as the mechanisms that cause the changes in properties. In addition, a replica of a production HPDC part was manufactured using AM to develop a prototype manufacturing process and to compare the results between them. The results showed that heat treating AM parts at 325C for 4 hours produced the closest yield strength to that of HPDC parts. However, the ductility was much greater for the AM parts due to differences in alloy composition and microstructure. For making an AM counterpart, the process developed was to manufacture the part with PBF-LB along with some tensile bars, heat treat the part on the build plate, machine any critical surfaces, remove the support material, and treat the surface with glass blasting to remove any remaining particles/powder on the surface. 
Program: MPAEM Materials Engineering Examiner:&nbsp;Eduard Hryha, IMS Supervisor: Torbjörn Larsson, Volvo Cars
Opponents: Shyam Thirusenthilnathan &amp; Shivsharan Muthusamy &nbsp; Date and time: 22 August 2024, 09.00-10.00 Location: <a rel="noopener" href="https://maps.chalmers.se/#d7061ac6-2c9b-4e70-a47c-d535ca17cfc3" target="_blank" title="Delta" data-anchor="#d7061ac6-2c9b-4e70-a47c-d535ca17cfc3">Delta</a>

"Challenges and Opportunities within Design for Additive Manufacturing"
Abstract: Additive manufacturing (AM) is transforming design and production by enabling the creation of complex geometries and enhancing product performance. Despite its potential, AM faces significant challenges, including file formatting issues, support structure design for intricate shapes, and the need for optimized manufacturing methods. To address these obstacles, simulation software has become invaluable, offering accurate predictions of material behavior and structural integrity during the printing process. This leads to improved designs and minimizes production issues, allowing engineers to innovate and create products with unique properties across industries such as aerospace and healthcare.&nbsp; A critical aspect of AM is designing support structures that stabilize parts during production while minimizing material waste and costs. Innovative techniques have emerged to optimize the balance between structural integrity and material efficiency, allowing for more complex designs with minimal support. Simulation tools are indispensable in identifying these solutions, enabling precise adjustments to build orientation, layer thickness, and other parameters to enhance part quality and reduce manufacturing time and costs. Interviews with designers and stakeholders have helped identify specific challenges they face and potential solutions. These discussions have contributed to understanding the Design for Additive Manufacturing (DFAM) workflow and predicting challenges in different departments. By plotting and tracking these challenges, insights from simulation software, file formatting, data transfer, and support structure design have been utilized to create standardized guidelines. This standardization helps in designing efficient support structures and optimizing post-processing methods, ultimately assisting designers and AM engineers in evaluating simulation results and optimizing the printing process and material use. Standardizing processes and guidelines for implementing AM across organizations is crucial for consistent success. This ensures that best practices are followed, reducing variability and enhancing the reliability of AM technologies. By establishing industry-wide standards, organizations can streamline operations, improve product quality, and reduce the learning curve associated with adopting new technologies. In conclusion, by addressing current challenges and embracing AM's potential, manufacturers can develop more reliable, efficient, and advanced products, solidifying AM as a cornerstone of modern manufacturing. 
Program: MPPDE Product Development Examiner: Eduard Hryha, IMS Supervisor: Sören Knuts and Petter Andersson, GKN Aerospace, and Gowtham Soundarapandiyan and Eduard Hryha, IMS
Opponents: Vikas Gangadharappa &amp; Rahul Dev Rampure &nbsp; Date and time: 22 August 2024, 10.00-11.00 Location: <a rel="noopener" href="https://maps.chalmers.se/#d7061ac6-2c9b-4e70-a47c-d535ca17cfc3" target="_blank" title="Delta" data-anchor="#d7061ac6-2c9b-4e70-a47c-d535ca17cfc3">Delta</a>

"High Performance 3D printed heat exchangers for marine applications"
Abstract: Heat Exchangers play a crucial role in many applications in terms of transferring heat between two fluids such as in engines, HVAC systems, etc. Volvo Penta uses a conventional heat exchanger which is used to cool the transmission oil where sea water is used as the coolant, however the conventional heat exchangers used on marine applications have a lot of drawbacks like corrosion due to salt water exposure, fouling due to small marine organisms, etc. These issues lead to a decrease in efficiency, higher maintenance cost and reduction in operational life span. These issues can be negated by many possible solutions out of which Additive Manufacturing (AM) could serve as one possible solution. The main aim of this project is to explore the possibility of having metal additive manufacturing as a solution to negate the issues which exist in the conventional shell and tube heat exchanger. By utilizing additive manufacturing, complex geometries can be achieved which is not possible in traditional manufacturing methods of heat exchangers which helps in the increase of heat transfer rate. Metal AM also has various options of materials with high corrosion resistance and better heat transferability. As the design freedom with Additive Manufacturing is more compared to the traditional methods, the possibility of making design of internal structures which enables comparatively easier cleaning which mitigates fouling which in turn helps in increasing the efficiency and life span of the heat exchanger. Based on the concerns like increased efficiency, longer life span and lower cost, few set of design iterations were generated. In these designs complex lattice geometries like gyroids and diamonds were incorporated as the internal structure. The different iterations of design are generated with various diameters, lengths and internal wall thicknesses, where each design iteration addresses different concern. In order to ensure the effectiveness of the designs, basic CFD simulations were conducted, however there are no comprehensive results for all the design iterations. Therefore, detailed CFD simulations are critical in order to make the design more feasible for the application. Moreover, prototyping and real time physical testing would be able to provide accuracy and closeness to the required results, which is not the scope of this project.
Program: MPPDE Product Development Examiner: Eduard Hryha, IMS Supervisor: Simon Carlsson, Volvo Penta &amp; Eduard Hryha, IMS
Opponents: Nils Nordström   Date and time: 22 August 2024, 11.00-12.00 Location: <a rel="noopener" href="https://maps.chalmers.se/#d7061ac6-2c9b-4e70-a47c-d535ca17cfc3" target="_blank" title="Delta" data-anchor="#d7061ac6-2c9b-4e70-a47c-d535ca17cfc3">Delta</a>

"Residual stress modelling for PBF-LB &nbsp;- A study of AdditiveLab as a meso-scale simulation tool in laser powder bed fusion"
Abstract:&nbsp; This thesis investigates the modeling of residual stress in laser powder bed fusion (PBF-LB) processes using AdditiveLab as a mesoscale simulation tool. The study aims to evaluate AdditiveLab as a process simulations tool for PBF-LB by replicating experimentally verified simulations, specifically focusing on 316L stainless steel. A literature review of simulation techniques was conducted, followed by transient thermal and thermomechanical simulations, and validation of AdditiveLab’s simulations against experimentally verified models from the literature. The simulations analyzed the thermal distribution, the dimensions of the melt pool, and the development of residual stress.
Program: MPSEB Structural Engineering and Building Technology Examiner: Ragnar Larsson, IMS Supervisor: David Ohlsson, RISE
Opponents: Elliot Sterneling and Mohannad Ellhajj &nbsp; Date and time: 2 September 2024, 14.00-15.00 Location: IMS Studio 3, <a rel="noopener" href="https://maps.chalmers.se/#091bd075-f9c1-4e51-bfb3-34267bf0e206" target="_blank" title="Hörsalsvägen 7B" data-anchor="#091bd075-f9c1-4e51-bfb3-34267bf0e206">Hörsalsvägen 7B,</a> floor 2

"<span style="font-size: 12.0pt; font-family: 'Aptos',sans-serif; mso-fareast-font-family: Aptos; mso-fareast-theme-font: minor-latin; mso-bidi-font-family: Aptos; color: black; mso-ansi-language: SV; mso-fareast-language: SV; mso-bidi-language: AR-SA;">Guided by sound--Exploring the use of spatial auditory cues for pedestrian navigation in urban environments"
Program: MPDES Industrial Design Engineering Examiner: Bijan Aryana, IMS Supervisor: Jana Sochor, IMS
Opponent: Xiaonan Lu &nbsp; Date and time: 16 September 2024, 09.00-10.00 Location: <a rel="noopener" href="https://maps.chalmers.se/#dcce1020-9ec8-11e8-a0b8-f1d1dcb8e3ff" target="_blank" title="Nordanvinden" data-anchor="#dcce1020-9ec8-11e8-a0b8-f1d1dcb8e3ff">Nordanvinden</a>

"<span style="font-size: 12.0pt; font-family: 'Aptos',sans-serif; mso-fareast-font-family: 'Times New Roman'; mso-bidi-font-family: Aptos; color: black; mso-ansi-language: SV; mso-fareast-language: SV; mso-bidi-language: AR-SA;">A Study on Commuting Therapy: Designing a Human-Vehicle Interaction System to Enhance the Commuting Experience with Emotion-based Multisensory Strategies"
Program: MPDES Industrial Design Engineering Examiner: Bijan Aryana, IMS Supervisors: Bijan Aryana, IMS and Antonio Cobaleda Cordero, Polestar
Opponent: Qihan Fu   Date and time: 16 September 2024, 10.00-11.00 Location: <a rel="noopener" href="https://maps.chalmers.se/#dcce1020-9ec8-11e8-a0b8-f1d1dcb8e3ff" target="_blank" title="Nordanvinden" data-anchor="#dcce1020-9ec8-11e8-a0b8-f1d1dcb8e3ff">Nordanvinden</a>

"The re-design of an electrical three-wheeler vehicle."
Abstract: This thesis explores the development of an enhanced exterior body design for OMotion AB’s electric vehicles (EVs) to address the growing demand for sustainable transportation. The study identifies issues with the previous vehicle model and integrates stakeholder requirements to create a new, optimized design. The exterior design is crucial for reducing air resistance, improving driving range, and enhancing user appeal. This project carefully considered parameters such as aerodynamics, manufacturability, and structural integrity in the design process. Given the constraints of a startup with limited resources, the design focused on minimizing changes to core components, ensuring compatibility with existing manufacturing processes. The result is an optimized and visually appealing exterior body design that aligns with the company’s strategic vision and production capabilities.
Program: MPPDE Product Development Examiner: Lars Lindkvist, IMS Supervisor: Lars Lindkvist, IMS
Opponent: Abhijit Sumant &amp; Swapnil Dawkare&nbsp; &nbsp; Date and time: 16 September 2024, 11.00-12.00 Location: <a rel="noopener" href="https://maps.chalmers.se/#4f7ab6fb-961f-492c-a721-541182fd27d8" target="_blank" title="Fabriken" data-anchor="#4f7ab6fb-961f-492c-a721-541182fd27d8">Fabriken</a>

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Presentation of master thesis

Master thesis presentations at Industrial and Materials Science

22 August 2024

09.00-10.00: Nils Nordström, MPAEM

10.00-11.00: Dasappa Ashoka Vijaya Kumar & Luqmaan Sidnekoppa, MPPDE

11.00-12.00: Shyam Sundar Balakrishnan Thirusenthilnathan & Shivsharan Muthusamy, MPPDE

2 September 2024

14.00-15.00: Haukur Friðriksson, MPSEB

16 September 2024

09.00-10.00: Qihan Fu, MPDES

10.00-11.00: Xiaonan Lu, MPDES

11.00-12.00: Ateeth Shetty & Vivek Doiphode, MPPDE