Small scale testing and cracking behaviour of Ni-based LMDp repairs (SCALABLE) - 2025-2027
Despite the development of high-performance alloys in the last decades, damage is inevitable to components functioning at high temperatures. A reasonable approach to reducing the scrap from such components is to repair them, which makes the loop of circularity shorter and minimizes greenhouse gas (GHG) emission. Among repair processes for metallic components, Laser Metal Deposition (LMD) has shown a unique and promising character, due to its flexibility and reliability in controlling various process parameters. Nonetheless, most current aero-engine metallic components are manufactured using techniques other than LMD, such as casting and forging. As a result, a deviation could exist between the microstructure and the mechanical performance of the substrate and the LMD repaired parts; a material compatibility challenge that can result in an immature failure, risking human lives. Therefore, to ensure the integrity, quality, and safety of repaired components, it is crucial to have a deep understanding of the material properties at the repair part, and at the interface between the repair and base parts. Considering the dimensional aspect of repairs in metallic components, conventional mechanical testing methods are not always applicable, and there is a need to develop reliable small-scale testing methods.
SCALABLE aims at developing and utilizing small-scale mechanical testing of repaired Ni-based superalloy aerospace components (e.g., IN-718, Haynes 282, or similar alloys), to understand their mechanical performance at the critical parts. The small-scale mechanical testing can be conducted inside the electron microscope to observe the material’s cracking behaviour. This gives us unprecedented information about material integrity that is essential for repair operation optimization. Besides competence development in small-scale testing in the aeronautic sector, SCALABLE contributes to increasing the lifetime of Ni-based components and improving sustainability by reducing the need for remanufacturing.
SCALABLE is a collaborative effort between Jönköping University (JU), GKN Aerospace Sweden AB (GKN), and Härdservice AB (Härdservice) to respond to the mentioned challenge. To be more specific, GKN will be providing the repaired components, and Härdservice will conduct the special heat treatment subsequent to the repair process, which will be followed by small-scale mechanical testing method development, validation, and a thorough materials characterization performed at JU.
Funded by:
SCALABLE aims at developing and utilizing small-scale mechanical testing of repaired Ni-based superalloy aerospace components (e.g., IN-718, Haynes 282, or similar alloys), to understand their mechanical performance at the critical parts. The small-scale mechanical testing can be conducted inside the electron microscope to observe the material’s cracking behaviour. This gives us unprecedented information about material integrity that is essential for repair operation optimization. Besides competence development in small-scale testing in the aeronautic sector, SCALABLE contributes to increasing the lifetime of Ni-based components and improving sustainability by reducing the need for remanufacturing.
SCALABLE is a collaborative effort between Jönköping University (JU), GKN Aerospace Sweden AB (GKN), and Härdservice AB (Härdservice) to respond to the mentioned challenge. To be more specific, GKN will be providing the repaired components, and Härdservice will conduct the special heat treatment subsequent to the repair process, which will be followed by small-scale mechanical testing method development, validation, and a thorough materials characterization performed at JU.
Funded by:
- KK-stiftelsen (Knowledge foundation in Sweden); 2.5 Mkr.
- Alireza Nazarahari (PI), Ehsan Ghassemali,
- Ceena Joseph (GKN Aerospace Sweden)
- Johan Kinell (Härdservice)
Surface modification of Ni-based superalloys for high temperature applications (SuNHigh) - 2025
Aluminising nickel-based (Ni-based) superalloys is a transformative surface treatment that can significantly enhance the performance and durability of components exposed to extreme environments and high temperatures. An aluminide coating can increase superalloys' oxidation and corrosion resistance, increasing component durability. This results in substantial cost savings and has a profound environmental impact by reducing the need for remanufacturing and repair, which is aligned with industry goals to lower carbon footprints and promote sustainability. SuNHigh will investigate the feasibility of various diffusion aluminising processes and study the effectiveness of the aluminide coating on the oxidation performance of the Ni-based alloy. In our holistic view, this is the base investigation for a longer-term research project where the efficient aluminising process is optimised for industrial jet-engine components, based on a deeper oxidation analysis, closer to the real working conditions (dynamic hot corrosion testing in a burning fuel environment). The overall aim is to generalise the idea of industrial aluminising various Ni-based superalloys in the long term to expand their high-temperature applications. In addition, the effect of such barrier layers on other performances, such as wet corrosion resistance, hydrogen embrittlement resistance, or high-temperature fatigue, can be studied in future full-scale projects.
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority) Metals & Minerals; 1 Mkr.
- Ehsan Ghassemali, Caterina Zanella
- Bengt Pettersson (GKN Aerospace Sweden)
The potential of LPBF Ti-V-Sn-Al-Zr-Mo (ATI23) alloy for aerospace applications (PROSPECT) - 2024-2026
This project “PROSPECT” investigates the potential of the newly developed TiVSnAlZrMo (ATI23) alloy for additive manufacturing (AM) and its suitability for aerospace applications. The newly produced materials from ATI for AM is claimed to offer superior printing capabilities with low distortion so that large-scale components could be manufactured when compared to the conventional Ti-6Al-4V alloy, making it more suitable for demanding aerospace components. The project's main goals are to understand, Hot Isostatic Pressing (HIP-ing) and heat treatment processes for optimized printed parameters of Laser Powder Bed Fusion (LPBF) produced ATI23 alloy. Further, to evaluate its microstructural, mechanical (tensile, and fatigue), and thermal/oxidation properties, and benchmark its performance with the conventional LPBF heat-treated Ti-6Al-4V.
PROSPECT aims to deliver new material knowledge, improve manufacturing capabilities, and create a competitive advantage for the participating SMEs. The primary users are aerospace manufacturers, particularly those involved in producing lightweight, high-strength components, such as GKN Aerospace, which is exploring the potential of ATI23 for applications such as gas turbine engines. SMEs involved will gain expertise in new aerospace materials, process optimization, and catering to the needs of aerospace standards, hence increasing Sweden's in-house supply chain capabilities.
The main applicant and coordinator is Dalarna University (DU), with other participants including GKN Aerospace Sweden (GKN) as an end user, the School of Engineering at Jönköping University (JTH), as well as two SMEs, MTC Powder Solution (MTC), and Härdservice (HS).
Funded by:
PROSPECT aims to deliver new material knowledge, improve manufacturing capabilities, and create a competitive advantage for the participating SMEs. The primary users are aerospace manufacturers, particularly those involved in producing lightweight, high-strength components, such as GKN Aerospace, which is exploring the potential of ATI23 for applications such as gas turbine engines. SMEs involved will gain expertise in new aerospace materials, process optimization, and catering to the needs of aerospace standards, hence increasing Sweden's in-house supply chain capabilities.
The main applicant and coordinator is Dalarna University (DU), with other participants including GKN Aerospace Sweden (GKN) as an end user, the School of Engineering at Jönköping University (JTH), as well as two SMEs, MTC Powder Solution (MTC), and Härdservice (HS).
Funded by:
- VINNOVA (Swedish Innovation Authority) NFFP8; 1.5 Mkr.
- Ehsan Ghassemali,
- Jayaraj Jayamani (PI) (Dalarna University)
- Ceena Joseph (GKN Aerospace Sweden)
- Johan Kinell (Härdservice)
- Karl-Johan Andrén (MTC)
Mission 0 House (Zero-emission reduction of metals) - 2025-2030
In 2025, Mission 0 House will launch a collaborative programme in partnership with the Jönköping University, Karlstad University, Mid Sweden University, University of Borås, University West, funded by the Knowledge Foundation and the industry. If you are passionate about advancing science in sustainable materials, committed to collaboration, and enthusiastic about the opportunity to drive change, we invite you to apply. This is your chance to be part of where scientific progress and industrial innovation meet to eliminate anthropogenic greenhouse gas emissions from materials and products. More info: here
Global metals production accounts for up to 10% of all GHG emissions, largely due to the carbon-intensive processes required to extract metals from carbonate, sulfidic, and oxidic minerals [1]. These minerals, used to produce both base metals and alloying elements for various engineering applications, either contain carbon—such as calcite (CaCO3)—or require significant amounts of carbon as a reducing agent, as seen in the processing of pyrolusite (MnO). Common alloying elements, manganese (Mn), chromium (Cr) and magnesium (Mg), are added to base metals to enhance their properties. However, converting the respective minerals to pure elements currently results in substantial emissions. For instance, at SSAB, a Mission 0 House partner, Mn is the alloying element responsible for the highest CO2 emissions (0.013kg CO2e/kg steel, or 55% of Scope 3 emissions), primarily due to the reduction of Mn ore with metallurgical coal. The key challenge is to explore carbon-free sources and processes for metal reduction, like Sweden’s HYBRIT project for iron (Fe) and the HalZero process for aluminium (Al), which utilize hydrogen (H2) or closed-loop CO2 systems. This project aims to explore novel strategies for carbon-free production of critical alloying elements, working with the metals industry to ensure maximum yield and practical implementation. The research is crucial for Sweden, as a leading European metal producer, to sustain its mining industry and achieve national carbon reduction goals. By strengthening collaboration between academia, industry, and Mission 0 House partners, the project will advance novel scientific understanding of ore-to-metal reduction processes and sustainable practices in metal production.
Funded by:
Global metals production accounts for up to 10% of all GHG emissions, largely due to the carbon-intensive processes required to extract metals from carbonate, sulfidic, and oxidic minerals [1]. These minerals, used to produce both base metals and alloying elements for various engineering applications, either contain carbon—such as calcite (CaCO3)—or require significant amounts of carbon as a reducing agent, as seen in the processing of pyrolusite (MnO). Common alloying elements, manganese (Mn), chromium (Cr) and magnesium (Mg), are added to base metals to enhance their properties. However, converting the respective minerals to pure elements currently results in substantial emissions. For instance, at SSAB, a Mission 0 House partner, Mn is the alloying element responsible for the highest CO2 emissions (0.013kg CO2e/kg steel, or 55% of Scope 3 emissions), primarily due to the reduction of Mn ore with metallurgical coal. The key challenge is to explore carbon-free sources and processes for metal reduction, like Sweden’s HYBRIT project for iron (Fe) and the HalZero process for aluminium (Al), which utilize hydrogen (H2) or closed-loop CO2 systems. This project aims to explore novel strategies for carbon-free production of critical alloying elements, working with the metals industry to ensure maximum yield and practical implementation. The research is crucial for Sweden, as a leading European metal producer, to sustain its mining industry and achieve national carbon reduction goals. By strengthening collaboration between academia, industry, and Mission 0 House partners, the project will advance novel scientific understanding of ore-to-metal reduction processes and sustainable practices in metal production.
Funded by:
- KK-stiftelsen (Knowledge foundation in Sweden); 10 Mkr.
- Ehsan Ghassemali, Anders Jarfors (PI), Taishi Matsushida, Lucia Lattanzi
- Polestar, Mission 0 House, SSAB,
Aluminium circularity by tolerant materials design and rethinking of material flow by IT-based system approach (ALCIRCUT) - 2025-2028
The scope of creating tolerant alloys that can allow wide chemical composition and certain impurity content, while still providing performance with respect to mechanical, thermal and corrosion behaviour, is one of the prime contributors to realize full material circularity. It can be viewed as a necessary means to facilitate use of recycled scrap, etc. The use of aluminium via different advanced casting technology and additive manufacturing is growing. Critical to this is the use of secondary aluminium. Hence, bringing tolerant material solutions in place that can fit both casting and additive manufacturing is of strategic and fundamental importance. This would provide the ultimate solution for circularity. In Sweden, there is a great chance to create sustainable value chains with full circularity, as well as the recycling industry. Even if the technical solutions are crucial, it is important to align these with a holistic approach involving coupling with cost modelling that incorporates sustainability criteria. We plan to act along four lines of development, Analytics-supported material value chain analysis, combining physicsbased laws with artificial intelligence (AI) supported analytics to arrive at sustainability and cost assessment criteria for initial materials and compositional design; In-depth theory approaches, using thermodynamics-based modelling and basic material-structure-property understanding to set the critical limits of alloy composition, Rapid testing and evaluation of promising material with high-throughput strategies and cost modelling and sustainability assessment along with these developments. The partners (Chalmers, JU, LU) will share their expertise and we will organize the work via a common post-doc, to provide unique and efficient work, with the target to present aluminium alloy(s) suitable for circularity.
Funded by:
Funded by:
- MISTRA (Swedish foundation for strategic environmental research); 6 Mkr.
- Ehsan Ghassemali
- Lars Nyborg (PI), Fang Liu (Chalmers University)
- Christina Windmark (Lund University)
Feedstock characterisation and small-scale mechanical testing of Titanium LMD Repairs (FAME) - 2024-2028
In the aerospace industry, reliable repair needs to be developed for critical components to be more sustainable. Among repair processes, Laser Metal Deposition (LMD) offers great promise, as proven in our previous projects. For the components manufactured using techniques other than LMD, the microstructure looks different at the LMD repair that is due to the intense heat induced by the laser. Further implementation of these repair techniques awaits an in-depth understanding of the material performance at the repair part and at the interface between the repair and substrate. Due to process dimensionality, this requires tailored and small-scale mechanical testing that has not been investigated extensively in the industry. FAME aims to tackle this challenge for Ti6242 cast components in aero engines. These components are used in the high-pressure compressors in the jet engine and are in high demand for repair. Accordingly, the FAME objectives are to develop small-scale testing to understand the deformation and cracking behavior of the Ti6242 repair and the interface between the repair and the casting. We will also study the LMD feedstock characteristics and their impact on the mechanical properties of LMD repairs. The findings will provide unprecedented knowledge for further optimization of the heat treatment process on the repair parts to improve the repair compatibilities to the castings. Besides, FAME aims to understand the scratch and wear mechanisms of Ti6242 repairs in sliding contact conditions, close to the real operating condition of the engine. We will correlate the microstructure to the mechanical and wear performance of Ti6242 alloy repairs for aero-engine applications.
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority) NFFP8; 6 Mkr.
- Ehsan Ghassemali, Sujith Subhash (PhD student), Alireza Nazarahari
- Ceena Joseph (GKN Aerospace Sweden)
- Jayaraj Jayamani (Dalarna University)
Advanced school on Circular Metal Components for the Swedish Manufacturing Industry (CIRCUMET) - 2023-2029
As an export-heavy sector that contributes to a large share of CO2 emissions, metal component manufacturing requires urgent competence supply focused on climate change. Moving towards a circular economy requires a revisit to the entire value chain of component manufacturing. This includes controlling the material and scrap flow and functional recycling of materials/components, i.e., sorting the material based on their chemical composition and then remelting alloys within a specific class into new advanced alloys. The use of scrap/reflow material is not new but the urgent need to fight the climate challenge requires new solutions and cannot be accomplished without needs-adapted training and competence development in the industry and academia. Such effort is also key for sustainable growth and competitiveness in the field, which can lead to improved income and employability for society as well. This emphasizes the important roles of future materials engineers that
must include circularity, sustainability, and digital and virtual solutions for the integration of materials and manufacturing.
CIRCUMET initiative has the ambition to develop and execute tailored and concise needs-motivated advanced courses (80-90 credits in total) related to mentioned topics for the metal component manufacturing sector, with the fight against climate change as the core concept. The main purpose is to provide the much-needed competence supply for the export-heavy Swedish component manufacturing industry that leads to increased competitiveness and sustainability at the international forefront, both technologically and commercially. Top-tier Swedish higher educational institutes (HEIs) active in metal component manufacturing (Tekniska Högskolan i Jönköping, Chalmers Tekniska Högskola, Högskolan Väst), create a comprehensive task force, together with RISE (SWECAST and IVF) as a research institute, and major industrial partners in the field (10 companies = Volvo Cars, Scania CV, GKN Aerospace, Ovako, Stena Metal International, Sandvik Coromant, AGES, Comptech, Husqvarna, Fagerhult). The industrial partners include both large companies and SMEs in the entire value chain of metal component manufacturing, from material suppliers to manufacturers, and end-users of metallic components in various sectors ranging from household appliances to automotive and aerospace. Moreover, CIRCUMET has gathered related associations that are integrator nodes for marrying the research and educational activities between the industry, HEIs, and RISE (Jernkontoret, Gjuteriföreningen, Svenskt Aluminium, FKG, and Tunga Fordon). To provide the business community with broader access to the competence supply at higher levels, the courses developed in CIRCUMET will be used as the base for developing an industrial research school.
Funded by:
must include circularity, sustainability, and digital and virtual solutions for the integration of materials and manufacturing.
CIRCUMET initiative has the ambition to develop and execute tailored and concise needs-motivated advanced courses (80-90 credits in total) related to mentioned topics for the metal component manufacturing sector, with the fight against climate change as the core concept. The main purpose is to provide the much-needed competence supply for the export-heavy Swedish component manufacturing industry that leads to increased competitiveness and sustainability at the international forefront, both technologically and commercially. Top-tier Swedish higher educational institutes (HEIs) active in metal component manufacturing (Tekniska Högskolan i Jönköping, Chalmers Tekniska Högskola, Högskolan Väst), create a comprehensive task force, together with RISE (SWECAST and IVF) as a research institute, and major industrial partners in the field (10 companies = Volvo Cars, Scania CV, GKN Aerospace, Ovako, Stena Metal International, Sandvik Coromant, AGES, Comptech, Husqvarna, Fagerhult). The industrial partners include both large companies and SMEs in the entire value chain of metal component manufacturing, from material suppliers to manufacturers, and end-users of metallic components in various sectors ranging from household appliances to automotive and aerospace. Moreover, CIRCUMET has gathered related associations that are integrator nodes for marrying the research and educational activities between the industry, HEIs, and RISE (Jernkontoret, Gjuteriföreningen, Svenskt Aluminium, FKG, and Tunga Fordon). To provide the business community with broader access to the competence supply at higher levels, the courses developed in CIRCUMET will be used as the base for developing an industrial research school.
Funded by:
- KK-stiftelsen (Knowledge foundation in Sweden); 30 Mkr.
- 4+10+5 partners in the consortium as mentioned above (PL: Ehsan Ghassemali)
Alloy development for hydrogen-related applications, part II (ALL4HYDRO II) - 2022-2025
Green Hydrogen, as a net-zero carbon emission energy source, is "the" solution to many current and future environmental and sustainability challenges. However, the efficient implementation of Hydrogen (H2) in society requires proper infrastructure; the development of such has been recently accelerated with more than 300-billion-dollar investment globally. The overall aim of the ALL4HYDRO II is to contribute to enabling the rapid development of demanded infrastructure supporting the efficient implementation of H2 in society; more specifically identifying the challenges and solutions for improving the performance of metallic materials that are used for components in the H2 value-chain, from production to distribution/storage and consumption. Accordingly, the project integrates high-throughput screening algorithms, thermodynamic calculations, and empirical modelling in modern alloy design strategies (i.e. high entropy alloys), as well as an experimental feasibility study for validation. Developing next-generation sustainable alloys with an improved lifetime in harsh environments will accelerate the implementation of H2 in many sectors, ranging from transportation to household. The results obtained in this project will impact and improve the efficiency of the H2 value chain, which enables reducing the associated costs and thus making this invaluable energy source more competitive against existing solutions (e.g., fossil fuels).
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority); 3.3 Mkr.
- Ehsan Ghassemali (PI)
- Patrick Conway (Jönköping University)
- Patrik Alnegren and Niklas Israelsson (Volvo Technology)
- Johan Bratberg (Thermo-Calc Software)
- Theresa Falkendal and Hans-olof Nilsson (Nilsson Energy)
- Steve Ooi (Ovako)
Climate-smart high-performance aluminium(ClimAl) - 2022-2025
The aluminum sheet content in a car is around 30 kg/car. And with 66 million cars producedannually, generates 31878 kton CO2 yearly. The use of 100% recycled sheet metal can reduce thisto 990 ktons globally. With green electricity, it could be zero. To move towards a sustainable industry, it is important to increase the use of recycled Al alloys. The high proportion of primarymaterials in sheet metal results in a significant carbon footprint in sheet metal products that areoften used in the transport industry. ClimAl aims to make a deeper analysis and identify critical trace elements that affect re-crystallization and deformation hardening, critical for both manufacturability and creative processand innovation. the resulting formability of the sheet shall be made. This is addressed byoptimizing both the alloy and the process path to enable a more flexible scrap mix with a minimalcarbon dioxide footprint and maximized stability with varying quality of incoming raw materials.The solution is thus to be achieved through a creative combination of both material and processinnovation.
This three-year project will also map the path to a carbon footprint to the zero-sum game withzero climate impact from sheet metal products with recycled aluminum. All parties in a potentialsupply chain will be involved with a raw material supplier (Stena Recycling), a sheet metalproducer (Gränges Finspång AB), an equipment developer (AP&T), a producer(FischerRohrtechnik) and an end-user) (Polestar) Automotive Sweden AB). Research, inno-vationand dissemination is done by Jönköping University and RISE AB.
Funded by:
This three-year project will also map the path to a carbon footprint to the zero-sum game withzero climate impact from sheet metal products with recycled aluminum. All parties in a potentialsupply chain will be involved with a raw material supplier (Stena Recycling), a sheet metalproducer (Gränges Finspång AB), an equipment developer (AP&T), a producer(FischerRohrtechnik) and an end-user) (Polestar) Automotive Sweden AB). Research, inno-vationand dissemination is done by Jönköping University and RISE AB.
Funded by:
- VINNOVA (Swedish Innovation Authority) Metalliska Material; 5 Mkr.
- Anders Jarfors (PI), Ehsan Ghassemali, Anton Rolseth (PhD student)
- Polestar, Stena Recycling, AP&T, Gränges, RISE
Active Clearance Control tuning through Coefficient of Thermal Expansion (A-tu-C) - 2023-2024
A critical aspect of jet engine efficiency is dictated by Active Clearance Control (ACC): the clearance between the turbine blade and casing. Engine design is optimized with dynamic ACC based on the blade and casing material properties. The property that determines the ACC, is the alloy’s coefficient of thermal expansion (CTE). Due to very demanding overall material property requirements in hot Cases, only certain materials (Waspaloy) can meet the current design needs. However, processing challenges for Waspaloy forging have created a demand to develop interchangeable materials. HAYNES® 282 Plate has potential in this regard. It then necessitates that the CTE of HAYNES® 282 can match that of Waspaloy. Preliminary results have shown that alternate processing and Heat Treatment (HT) can yield CTE values close to that of Waspaloy. However, the extent CTE is altered with phase constituents through processing and HT remains unknown. Hence, understanding the impact on phase type, phase volume fraction (g’, Carbide type) as a function of processing and HT can provide a versatile tool for material selection. This defines the aim of A-tu-C project.
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority) NFFP8; 1.25 Mkr.
- Ehsan Ghassemali, Alireza Nazarahari
- Prajina Bhattacharya (GKN Aerospace Sweden)
- David Linder (Questek Europe)
- Greta Lindwall (KTH)
Small scale tensile testing of Ti LMDp repairs (SMART) - 2023-2024
Material compatibility in repair is critical since it determines the quality and safety measures. Laser Metal Deposition-powder (LMDp) is widely used for repairing damaged metallic components. But due to the intense laser heat, the deposited material has a different microstructure & property than the substrate. Thus, further innovation in and implementation of repair operations awaits an in-depth understanding of material performance at various sections of the repair. SMART aims at utilising and developing small-scale mechanical testing of repaired Ti-6Al-4V components, to understand their mechanical performance at the critical parts. The test is conducted inside the electron microscope to observe the material’s cracking behaviour. This gives unprecedented information about material integrity that is essential for repair operation optimization. “Repair” here means building significant volume of material. Besides competence development in small-scale testing in the aeronautic sector, SMART contributes to increasing lifetime of Ti-based components and improving the sustainability by reducing the need for remanufacturing.
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority) NFFP8; 1.5 Mkr.
- Ehsan Ghassemali, Alireza Nazarahari
- Ceena Joseph (GKN Aerospace Sweden)
- Jayaraj Jayamani (Dalarna University)
Low density wear resistant Fe-based alloy development (LOWEAR) - 2022-2023
LOWEAR aims to understand the wear mechanisms of existing steel alloys and consequently develop and produce (cast) up to two lightweight wear-resistant Fe-based alloys, based on the design criteria established by the project consortium. Modern alloy design strategies such as high-entropy alloys and "high-throughput screening" are used. In the long term, the acquired knowledge provides unique guidance for developing metal alloys, even beyond the goals of this project. Developing light wear-resistant alloys is an increasing eligibility requirement in the metal industry towards more durability, mainly associated with the frequent need for service, maintenance, and remanufacturing. In many sectors such as transportation, in addition to wear performance, component weight is a factor that has a direct correlation to fuel consumption. LOWEAR is the first step in our holistic approach to the development and industrial implementation of the next generation of wear-resistant, low-density alloys.
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority); 800 Kkr.
- Ehsan Ghassemali (PI)
- Patrick Conway (Jönköping University)
- Latifa Melk (Sandvik SRP)
- Hyunwoo Kim (Volvo Construction Equipment)
Webinars for quick and effective lifelong learning in metal and polymer industry (WEBLEARN) - 2020-2022
WEBLEARN provides the platform for conducting biweekly webinars related to metal and polymer component manufacturing.
The development time that has been released in many companies due to Covid-19 crisis is a golden opportunity for competence development, which is crucial for Swedish industry to remain competitive globally. Metal and polymer manufacturing industries, as two of the most commercially impactful industries, will be the target for our competence development packages. The developed skills will equip local industries with a quicker implementation of innovation, improving product quality, raising global competitiveness, as well as a quicker recovery after the crisis is over.
WEBLEARN provides quick and effective competence development packages (webinars) in the field of "engineering component manufacturing" for metal and polymer industry at the advanced (Master) level. Compare to conventional long-term educational efforts, our webinars with specific topics will be a "spot-on" and state-of-the-art knowledge transfer based on current industrial needs, that facilitates a quick impact to the industry even within less than a year. Besides focusing on technical challenges, we aim to conduct webinars related to sustainability and environmental challenges in metal and polymer industry. Moreover, WEBLEARN enables networking among professionals working in different industrial sectors that can lead to further intersectoral innovation and collaboration. For professionals working in the industry, WEBLEARN also offers access to international guest lecturers that will be involved in our webinars, thanks to our extended international network.
Funded by:
The development time that has been released in many companies due to Covid-19 crisis is a golden opportunity for competence development, which is crucial for Swedish industry to remain competitive globally. Metal and polymer manufacturing industries, as two of the most commercially impactful industries, will be the target for our competence development packages. The developed skills will equip local industries with a quicker implementation of innovation, improving product quality, raising global competitiveness, as well as a quicker recovery after the crisis is over.
WEBLEARN provides quick and effective competence development packages (webinars) in the field of "engineering component manufacturing" for metal and polymer industry at the advanced (Master) level. Compare to conventional long-term educational efforts, our webinars with specific topics will be a "spot-on" and state-of-the-art knowledge transfer based on current industrial needs, that facilitates a quick impact to the industry even within less than a year. Besides focusing on technical challenges, we aim to conduct webinars related to sustainability and environmental challenges in metal and polymer industry. Moreover, WEBLEARN enables networking among professionals working in different industrial sectors that can lead to further intersectoral innovation and collaboration. For professionals working in the industry, WEBLEARN also offers access to international guest lecturers that will be involved in our webinars, thanks to our extended international network.
Funded by:
- KKs (Knowledge Foundation, Sweden); 3 Mkr.
- Ehsan Ghassemali (PL)
- Madelene Zetterlind (Deputy PL)
- Stefan Brolin (Marketing)
- Staff at the department of materials and manufacturing, Jönköping University (Lecturers)
- Guest lecturers from more than 20 companies and/or RIs within EU
Lattice distortions and short range order in refractory high entropy alloys - 2022-2026
High entropy alloys (HEAs), where multiple elements are present in close to equimolar ratios, show great potential for use in high performance applications. In particular, HEAs based on refractory elements (RHEAs) have been shown to exhibit exceptional properties at very high homologous temperatures. The PI of the proposed project is currently developing RHEAs, targeting aerospace and energy applications, focused on achieving alloys with increased ductility and retained high temperature strength. Designing RHEAs with balanced mechanical properties requires substantial knowledge about fundamental phenomenon occurring at atomic level The proposed project will complement the ongoing research by specifically addressing two critical aspects for successful alloy development – the occurrence and extent of (i) local lattice distortions (LLD) and (ii) short range order (SRO) in RHEAs. The use of neutron scattering, in particular the use of total scattering and pair distribution function (PDF) analysis provide unique possibilities to understand these phenomena.
Funded by:
Funded by:
- SWEDNESS-SSF (Swedish foundation for strategic research); 5 Mkr (full coverage of the PhD student).
- Sheng Guo (Chalmers, PL, main supervisor)
- Magnus Colliander (Chalmers, co-supervisor)
- Ehsan Ghassemali (JU, co-supervisor)
ALuminium Two O five Structures (ALTOS) - 2020-2022
GKN Aerospace, RISE SWECAST and Jönköping University in Sweden will work together with the German foundry - ARCONIC Bestwig - with the target of creating the ability to introduce the new high strength alloy A205 in cast jet engine structures. The Swedish partners have worked with AEROMET Ltd (the alloy patent holder) in previous projects to create a solid background in the characteristics of the alloy. ARCONIC Bestwig has started to cast the alloy and they want to bring the new alloy into their business too. This project aims to combine the competence and strength of the Swedish team and ARCONIC Bestwig and create a wider supplier base for the alloy. Additionally, we aim to improve some of the deficiencies in fatigue properties that have been found in the background work by using ARCONIC Bestwig’s very controlled HERO casting process.
Funded by:
Funded by:
- Vinnova (Swedish authority for innovation); 4.5 Mkr (1.25 Mkr for JU).
- GKN Aerospace (PL)
- RISE (Research Institute of Sweden)
- JU
- Arconic (Germany)
Alloy development for Hydrogen-related applications (ALL4HYDRO) - 2021-2022
Green Hydrogen, as a net-zero carbon emission energy source, is "the" solution to many current and future environmental and sustainability challenges. However, the efficient implementation of Hydrogen (H2) in society requires proper infrastructure; the development of such has been recently accelerated with more than 300-billion-dollar investment globally. The overall aim of the ALL4HYDRO project is to contribute to enabling the rapid development of demanded infrastructure supporting the efficient implementation of H2 in society; more specifically identifying the challenges and solutions for improving the performance of metallic materials that are used for components in the H2 value-chain, from production to distribution/storage and consumption. Accordingly, the project integrates high-throughput screening algorithms, thermodynamic calculations, and empirical modelling in modern alloy design strategies (i.e. high entropy alloys), as well as an experimental feasibility study for validation. Developing next-generation sustainable alloys with an improved lifetime in harsh environments will accelerate the implementation of H2 in many sectors, ranging from transportation to household. The results obtained in this project will impact and improve the efficiency of the H2 value chain, which enables reducing the associated costs and thus making this invaluable energy source more competitive against existing solutions (e.g., fossil fuels).
Funded by:
Funded by:
- VINNOVA (Swedish Innovation Authority); 825 Kkr.
- Ehsan Ghassemali (PI)
- Patrick Conway (Jönköping University)
- Patrik Alnegren and Niklas Israelsson (Volvo Technology)
- Johan Bratberg (Thermo-Calc Software)
- Theresa Falkendal and Hans-olof Nilsson (Nilsson Energy)
- Jonathan Lane (Linde Gas)
NOVEL LIGHT ALLOY DEVELOPMENT BASED ON THE HIGH ENTROPY CONCEPT; part II (NOVELA II) - 2021-2023
NOVELA II is an extension of NOVELA projects that aims at developing modern high-performance Al- and Ti-based alloys that possess improved strength over current alloys while reducing the density. The replacement of heavy parts by the lightweight high-performance components reduces energy (fuel) consumption, and thus the carbon footprint in the many industries that are end-users of metallic parts; such as transportation and household sectors. Beside component design optimization, fulfilling the lightweight demand requires further development of advanced high-performance light alloys. This research combines traditional alloy design routines (e.g., precipitation hardening) with a ground-breaking alloy design strategy (high entropy alloys) to develop a new generation of Al and Ti alloys. The goal is to develop light alloys with improved specific strength (strength to density ratio), and structural stability compared to the existing Al- (and Ti-) based alloys at room and elevated temperatures, up to 250°C in this project. The project integrates computational thermodynamics and experimental investigations to design, produce and characterize Al- and Ti-based medium-to-high entropy alloys. Successful implementation of the project idea will contribute to the development of advanced high-performance alloy solution for harsh environment applications.
Funded by:
Funded by:
- KK-stiftelsen (Knowledge Foundation in Sweden); 2.5 Mkr.
- Dr. Patrick Conway (PI)
- Ehsan Ghassemali
- Anders Sjunnesson and Dr. Bengt Pettersson (GKN aerospace sweden)
- Johan Bratberg (Thermo-Calc Software)
NOVEL LIGHT ALLOY DEVELOPMENT BASED ON THE HIGH ENTROPY CONCEPT (NOVELA) - 2018-2021
The NOVELA project aims at developing modern high-performance Al-based alloys that possess improved strength over current high-strength Al alloys while reducing the density. The replacement of heavy parts by the lightweight high-performance components reduces energy
(fuel) consumption, and thus the carbon footprint in the many industries that are end-users of metallic parts; such as transportation and household sectors. Beside component design optimization, fulfilling the lightweight demand requires further development of advanced high-performance light alloys. Development of Al alloys as one of the most commonly used light alloys has been stagnated due to the limitations set by conventional alloy design routines. This feasibility research combines traditional alloy design routines (e.g., precipitation hardening) with a ground-breaking alloy design strategy (high entropy alloys) to develop a new generation of Al alloys. The goal is to develop light alloys with improved specific strength (strength to density ratio), and structural stability compared to the existing Al- (and AlTi-) based alloys at room and elevated temperatures, up to 250°C in this project. The project integrates computational thermodynamics and experimental investigations to design, produce and characterize Al-based medium-to-high entropy alloys. Successful implementation of the project idea w ill contribute to the development of advanced high-performance alloy solution for harsh environment applications.
Funded by:
(fuel) consumption, and thus the carbon footprint in the many industries that are end-users of metallic parts; such as transportation and household sectors. Beside component design optimization, fulfilling the lightweight demand requires further development of advanced high-performance light alloys. Development of Al alloys as one of the most commonly used light alloys has been stagnated due to the limitations set by conventional alloy design routines. This feasibility research combines traditional alloy design routines (e.g., precipitation hardening) with a ground-breaking alloy design strategy (high entropy alloys) to develop a new generation of Al alloys. The goal is to develop light alloys with improved specific strength (strength to density ratio), and structural stability compared to the existing Al- (and AlTi-) based alloys at room and elevated temperatures, up to 250°C in this project. The project integrates computational thermodynamics and experimental investigations to design, produce and characterize Al-based medium-to-high entropy alloys. Successful implementation of the project idea w ill contribute to the development of advanced high-performance alloy solution for harsh environment applications.
Funded by:
- VINNOVA (Swedish Innovation Authority); 800 Kkr.
- Assist. Prof. Ehsan Ghassemali (PI)
- Dr. Patrick Conway (Jönköping University)
- Anders Sjunnesson and Dr. Bengt Pettersson (GKN aerospace sweden)
- Linus Liljeblad, Josef Emme (Husqvarna group; power parts)
- Johan Bratberg (Thermo-Calc Software)
ALLOY DEVELOPMENT FOR HIGH TEMPERATURE APPLICATIONS USING THE HIGH ENTROPY CONCEPT; part II (ALIGHT II) - 2018-2022
Following the successful feasibility study project (ALigHT), ALigHT II is focused on further development of Ni-based superalloys for high performance at elevated temperature applications. Novel methodologies such as High Entropy Alloy concept will be used for such purposes. A combination of super-saturated solid solution and precipitation hardening mechanisms will be utilized for high temperature strengthening of the alloys. Microstructural and mechanical investigation of the modified alloys will be the main focus of the project. The final goal is to propose an alloy, with proper precessability" for industrial applications at harsh conditions.
The project runs from Aug. 2018 to June 2021, with a very close collaboration with industrial partners.
Funded by:
The project runs from Aug. 2018 to June 2021, with a very close collaboration with industrial partners.
Funded by:
- VINNOVA (Swedish Innovation Authority); ~3.6 Mkr.
- Assist. Prof. Ehsan Ghassemali (PI)
- Assoc. Prof. Sheng Guo (Chalmers University of Technology)
- Dr. Patrick Conway; Assoc. Prof. Taishi Matsushita; Assoc. Prof. Caterina Zanella (Jönköping University)
- Dr. Guocai Chai and Dr. Tom Eriksson (Sandvik Materials Technology)
- Dr. Anders Sjunnesson and Dr. Bengt Pettersson (GKN aerospace sweden)
- Dr. Taina Vuoristo (SWERIM)
Strategic alloy design initiative (STRAIT) - 2018-2020
The project aims for providing a unique environment for focused research and development on design and production of modern alloys, that is aligned with the Innovation Partnership Programme in Sweden. Within this strategic fund, we are exploring and developing various advanced alloy (metallic material) design strategies such as High Entropy Alloys (HEAs) and related concepts. A big effort is devoted to expanding the research collaboration in the field of alloy development, not only in Sweden but also internationally.
Therefore, we warmly invite all research groups in the field of metallic alloys development to contact for discussing possible collaborations.
Funded by:
Therefore, we warmly invite all research groups in the field of metallic alloys development to contact for discussing possible collaborations.
Funded by:
- School of Engineering; Jönköping University; ~1.7 Mkr
- Dr. Ehsan Ghassemali (PI)
- Dr. Patrick Conway (Postdoc)
- Assoc. Prof. Caterina Zanella (Assoc. Prof.)
- Prof. Anders Jarfors (Prof.)
Mechanical properties of high entropy alloys - Ongoing (Collaboration with IITK india)
By definition, High Entropy Alloys (HEAs), that are also called multi-component alloys, contain five or more principal alloying elements in equiatomic or near equiatomic proportions. Such an alloy design could lead to outstanding and unique mechanical, physical and chemical properties at harsh conditions such as cryogenic and high temperature applications. To date there has been number of studies on investigating the mechanical properties of these alloys in various temperature ranages. The deformation mechanism of most of these alloys are still controvertial though.
The main aim of this collaborative research project is to understand the crack initiation and propagation mechanims in single- and dual-phase high entropy alloys. In-situ tensile test at room and elevated temperatures in a high resolution scanning electron microscope is used for the study. The alloy that is in the focus now is AlCoCrFeNi. Other types of HEAs including Eutectic HEAs are of interest to be examined using the same technique.
Team Members:
The main aim of this collaborative research project is to understand the crack initiation and propagation mechanims in single- and dual-phase high entropy alloys. In-situ tensile test at room and elevated temperatures in a high resolution scanning electron microscope is used for the study. The alloy that is in the focus now is AlCoCrFeNi. Other types of HEAs including Eutectic HEAs are of interest to be examined using the same technique.
Team Members:
- Dr. Ehsan Ghassemali, Dr. Patrick Conway (Characterization), Sweden
- Prof. Krishanu Biswas (Alloy design and production), India
- Assoc. Prof. N.P. Gurau (Alloy design and production), India
- Rashma S. (Alloy production), India
Foundry Master - 2013-2019
Foundry Master is an educational project aiming for developing an online Master programme in metal casting. The online Master’s programme in Materials and Manufacturing is developed in a collaboration between the School of Engineering, Swedish Foundry Association, Swerea SWECAST and the foundry industry. The industry is involved in lecturers, with expertise, study visits, and through a collaboration on relevant projects. The courses are in English and are web-based, for example through video lectures, discussion forums and e-meetings. You will study half-time, which means that you can choose to combine your studies with work.
The Master’s programme is interdisciplinary and includes aspects such as:
The Master’s programme is interdisciplinary and includes aspects such as:
- solidification of cast metals, cast metals processes, heat treatment, defect and failure analysis
- the relationship between mould filling, solidification of metals, defect formation and performance of castings
- predictive tools to simulate the complex relationship between the cast metal and the processes that make it possible for the engineer to further optimize cast components without compromising performance.
- KK stiftelsen (Knowledge foundation), Sweden; ~22 Mkr
- Dr. Ehsan Ghassemali (Project leader; since Jan. 2018)
- Madelene Zetterlind (deputy project leader)
- Assoc. Prof. Nils-Eric Andersson (programme manager)
- All other teachers at the department of Materials and Manufacturing, Jönköping University
- 14 industrial partners as well as Swedish Foundry Association and Swerea SWECAST
High integrity cast components in Al‐Si alloys - 2016-2018
Some of the major driving forces for the development of Al-Si cast alloys are high strength to weight ratio, superior wear resistance, low coefficient of thermal expansion, high corrosion resistance, low cost and excellent castability, which makes them potential candidate materials for a number of applications in automobiles and other engineering sectors.
Permanent mould casting processes, and particularly the High Pressure Die Casting (HPDC) process, have been widely used to manufacture a large variety of products with high dimensional accuracy and productivity. Given the complexity of HPDC process, the achievement of targeted levels/zero defect castings remains a challenge. In order to control the level of defect and hence being able to produce sound and near zero defect castings, cumulative research need to be carried out in order to understand the relationships between melt treatment procedures, alloying elements, component design and the manufacturing process on the mechanical properties. There is also a need to work towards optimization of the HPDC process to be able to manufacture high performance Al cast components.
The current project idea stems from the vision to create deeper knowledge towards obtaining high integrity and sustainable castings and hence study the interactions between the varieties of factors involved in the production of castings. This project offers therefore a unique and novel methodology to work towards the optimization of the various factors involved in the component manufacturing in order to obtain high quality HPDC Al castings.
Funded by:
Team Members:
Permanent mould casting processes, and particularly the High Pressure Die Casting (HPDC) process, have been widely used to manufacture a large variety of products with high dimensional accuracy and productivity. Given the complexity of HPDC process, the achievement of targeted levels/zero defect castings remains a challenge. In order to control the level of defect and hence being able to produce sound and near zero defect castings, cumulative research need to be carried out in order to understand the relationships between melt treatment procedures, alloying elements, component design and the manufacturing process on the mechanical properties. There is also a need to work towards optimization of the HPDC process to be able to manufacture high performance Al cast components.
The current project idea stems from the vision to create deeper knowledge towards obtaining high integrity and sustainable castings and hence study the interactions between the varieties of factors involved in the production of castings. This project offers therefore a unique and novel methodology to work towards the optimization of the various factors involved in the component manufacturing in order to obtain high quality HPDC Al castings.
Funded by:
- Jönköping Län Regional Funding Agency; ~4 Mkr
Team Members:
- Dr. Ehsan Ghassemali (Project leader)
- Prof. Salem Seifeddine (Supervisor)
- Marting Riestra (Ph.D. candidate)
- Toni Bogdanoff (Research assistant)
ALloy development for High Temperature applications using the high entropy concept (ALigHT) - 2017-2018
This feasibility study aims at using the High Entropy Alloys (HEAs) concept for the development of existing Ni-based high Fe-Cr superalloys, to widen their application range to broader range of temperatures and/or highly corrosive environments. HEAs are a new type of advanced metal alloys, containing more than 5 different elements, usually in equimolar proportions. HEAs have demonstrated outstanding thermomechanical properties and high resistance in chemically aggressive environments. This has made HEAs one of the best candidates for strategically demanding applications in the energy, transport and aerospace sectors. Despite their appealing features, HEAs production has not yet been commercialized, mainly due to technical challenges or high production costs and raw material costs.
The obtained knowledge in this project provides guidance for development of all types of alloys, even beyond the objectives of this project such as steel, light alloys and composites. This creates the potential for expanding the metallic materials market, specifically for sustainable products in strategic sectors such as energy, transport and aviation.
The project runs until April 2017, with a great chance of being extended into a full-term project for another 3 years.
Funded by:
The obtained knowledge in this project provides guidance for development of all types of alloys, even beyond the objectives of this project such as steel, light alloys and composites. This creates the potential for expanding the metallic materials market, specifically for sustainable products in strategic sectors such as energy, transport and aviation.
The project runs until April 2017, with a great chance of being extended into a full-term project for another 3 years.
Funded by:
- VINNOVA (Swedish government funding agency); ~1 Mkr
- Dr. Ehsan Ghassemali (Project leader)
- Assoc. Prof. Sheng Guo (Chalmers University of Technology)
- Assoc. Prof. Taishi Matsushita; Assoc. Prof. Caterina Zanella; Prof. Salem Seifeddine (Jönköping University)
- Dr. Guocai Chai (Sandvik Materials Technology)
- Dr. Anders Sjunnesson (GKN aerospace sweden)
- Dr. Taina Vuoristo (Swerea KIMAB)
- Dr. Henrik Hedlund (Saan Energi)
Deformation properties of high performance ductile cast iron - 2014-2017
Ductile iron is one of the most cost-effective materials for producing cast components when a good combination of ductility and strength is required. Increasing silicon content of ductile iron to more than 3.5 Wt% will result in production of high silicon ductile iron grades. Silicon has a strong ferrite stabilizing effect and it increases the strength of ductile iron with solid solution hardening. High silicon ductile iron has some excellent properties such as high strength and good machinability. Despite the fact that many ductile iron grades have been well tested, there is still a lack of knowledge about mechanical properties of high silicon ductile iron grades. Focusing on this issue, the aim of this project is to investigate microstructural influence on mechanical and deformation properties of ordinary and high silicon ductile iron. The project is aimed to show how the microstructure changes during the deformation and how solid solution hardening affects the mechanical properties. Digital image correlation (DIC) and in-situ SEM/OM/EBSD are essential parts of experiments in this study. Eventually, the obtained data can be used for simulation tools to predict the properties of ordinary and solution hardened ductile iron.
Funded by:
Funded by:
- KK stiftelsen (Knowledge foundation), Sweden; ~15 Mkr
- Prof. Anders E.W. Jarfors (Project leader)
- Dr. Ehsan Ghassemali (Co-supervisor)
- Dr. Kent Salamonson (Co-supervisor)
- Keivan Amiri Kasvayee (Ph.D. student)
Mechanical properties of the high pressure die cast Mg alloy (Az91D) - 2014-2017
High performance light alloys are very demanding specifically in automotive and aerospace industries. AZ91D is one of the most widely used magnesium die cast alloy and has an excellent combination of mechanical properties, corrosion resistance, and castability. One of the main challenges in application of this alloy is decline of the mechanical properties at relatively high temperature applications. In this ongoing project, the relationship between the microstructure (particularly the shape factor, fractional volume and spatial connectivity of gamma intermetallic phase) and mechanical properties of the AZ91D alloys is being studied at the micro-scale. Using physically-based models, it is tried to understand the alloy behavior during deformation at higher temperatures. Ex-situ and in-situ EBSD studies is used to validate modeling activities. Alloy design and optimization of the heat-treatment processes is also considered as future work for optimization of the mechanical properties of the prototype components.
Funded by:
Team members:
Funded by:
- KK stiftelsen (Knowledge foundation), Sweden; ~15 Mkr
Team members:
- Prof. Anders E.W. Jarfors (Project leader)
- Assoc. Prof. Nils-Eric Andersson (Co-supervisor)
- Ms. Hoda Dini (PhD student)
Procurement of a new FIB/FESEM instrument - 2014-2015
Using Focused Ion Beam (FIB) technology it is possible to conduct 3D microstructural/chemical investigations in the FESEM. This can broaden up the scientific research capabilities in many aspects. Combination of the 3D characterization and in-situ investigations can provide a state-of-the-art facility for in-depth metallurgical and materials science studies.
Dr. Ghassemali was the project leader for procurement of a modern FIB/FESEM together with required attachments for 3D EBSD, 3D EDS, WDS, In-situ tensile/compression, In-situ heating (up to 800C), STEM and BSE imaging.
Funded by:
Team Members:
Dr. Ghassemali was the project leader for procurement of a modern FIB/FESEM together with required attachments for 3D EBSD, 3D EDS, WDS, In-situ tensile/compression, In-situ heating (up to 800C), STEM and BSE imaging.
Funded by:
- Jönköping University, Sweden; ~12 Mkr
Team Members:
- Dr. Ehsan Ghassemali (Project leader)
- Prof. Anders Jarfors (Prof.)
- Mr. Jörgen Bloom (Technician)
Optimization of a progressive microforming process and in-process material behavior - 2009-2013
Production of miniaturized metallic parts has been a demanding trend in many technical areas such as electronics and medical industries. Among all the micro-manufacturing techniques, micro-forming is well-suited for efficient production of metallic micro-parts due to its unique advantages, including: (i) near-net shape production, (ii) improved mechanical properties of the final product, together with (iii) the mass production capability and (iv) lower manufacturing cost.Despite the extensive of research in this field, microforming processes have not been adopted extensively for mass production in the industry. This is so as there are issues such as handling of micro-parts and removal of the formed parts from dies without damage, which require further process and manufacturing system design and development.
A progressive pin forming die system was developed in this study, with the following advantages over other existing micro-forming technologies: (i) it can circumvent the handling issues of small billets needed for extruding pins of very small diameter; (ii) such a process uses a strip as the workpiece and is more productive since a progressive process can be implemented; and (iii) instead of ejecting, the system uses a blanking process to remove the formed pin from the strip material, eliminating the possibility of buckling damage if a counter punch is used as an ejector.
There is a lack of detailed studies on metallurgical aspects of micro-forming processes, and none exist in the area of progressive microforming. There is also very limited understanding on the microstructure’s influence on the final micro-product properties. This is, however, very critical for process optimization. In addition to the experimental studies, an analytical modeling technique was developed to provide a universal solution for the process.
Funded by:
Team Members:
A progressive pin forming die system was developed in this study, with the following advantages over other existing micro-forming technologies: (i) it can circumvent the handling issues of small billets needed for extruding pins of very small diameter; (ii) such a process uses a strip as the workpiece and is more productive since a progressive process can be implemented; and (iii) instead of ejecting, the system uses a blanking process to remove the formed pin from the strip material, eliminating the possibility of buckling damage if a counter punch is used as an ejector.
There is a lack of detailed studies on metallurgical aspects of micro-forming processes, and none exist in the area of progressive microforming. There is also very limited understanding on the microstructure’s influence on the final micro-product properties. This is, however, very critical for process optimization. In addition to the experimental studies, an analytical modeling technique was developed to provide a universal solution for the process.
Funded by:
- Nanyang Technological University (NTU)
- Agency for Science, Technology and Research, Singapore (A*STAR)
- Singapore Institute of Manufacturing Technology (SIMTech)
Team Members:
- Assoc. Prof. Tan Ming Jen (Main supervisor)
- Prof. Anders E.W. Jarfors (Co-supervisor)
- Ehsan Ghassemali (PhD student)
- Dr. Samuel C.V. Lim (co-supervisor)
- Dr. Chua Beng Wah (co-supervisor)
Thermomechanical processing of a low carbon steel - 2006-2009
Among the different strengthening mechanisms of metals, grain refinement is the only method that has the capability of improving both strength and toughness simultaneously. Research on processing ultrafined and nanostructured materials has grown enormously over the last two decades. Numerous approaches, such as alloying, controlled rolling combined with accelerated cooling, plastic deformation and recrystallization (PDR), gas condensation with subsequent consolidation, ball-milling, amorphous phase crystallization, strain-induced transformation from austenite to ferrite, high pressure torsion (HPT), equal-channel angular pressing (ECAP) are used to reduce the materials grain size down to submicron and even nanometers. Among these methods, PDR is one of the advanced thermo-mechanical processing and is a very attractive method with a number of advantages. Firstly, it can produce massive samples without microporosity and contamination, for further mechanical testing and physicochemical examination to reveal the intrinsic properties of nanocrystalline materials. Secondly, PDR can be easily adapted to large-scale industrial production.One of the PDR routes to fabricate ultrafine grained steel includes cold rolling of a martensite starting microstructure in a low carbon steel and subsequent annealing. The final microstructure was reported to consist of ultrafine ferrite grains and uniformly precipitated carbides. The formation of an ultrafine microstructure was attributed to the fine martensite starting microstructure, which augmented the effect of plastic deformation enhancing grain subdivision. The high dislocation density as a result of cold rolling and the high concentration of solute carbon atoms in the martensite were also expected to facilitate grain subdivision by causing inhomogeneous deformation. The aim of this work was to investigate the microstructural evolution of a 0.13 wt% plain carbon steel during cold-rolling and subsequent annealing at various temperatures.
Funded by:
Team Members:
Funded by:
- Isfahan University of Technology
- Mobarakeh Steel Co.
Team Members:
- Prof. Abbas Najafizadeh (Main supervisor)
- Assoc. Prof. Ahmad Kermanpur (Co-supervisor)
- Ehsan Ghassemali (Master student)
- Mohsen Asgari Paykani (Bachelor student)
Synthesis of metallic Nanoparticles By Electromagnetic Levitational Gas Condensation Method - 2005-2007
Nanoparticles are experiencing a rapid development due to their existing and/or potential applications. The fabrication technology of aluminum nanoparticles includes a wide range of vapor (e.g., gas condensation), liquid (e.g., wet chemical) and solid state processing (e.g., mechanical milling) routes. Although the first successful experimental work for
the electromagnetic levitation melting was performed by Okress et al. in 1952, this process has recently been introduced as a promising method for the synthesis of nanoparticles. Among all the other production methods of nanoparticles, this method can result in a much higher production rate and a lower level of contamination.
Due to the difficulty in the levitation melting of alloys, no extensive works have been reported so far on the use of this technology
for different nanomaterials. In the present work, a novel electromagnetic levitational gas condensation (ELGC) system was designed and manufactured for the synthesis of aluminum nanoparticles. Pure aluminum as the charge metal and argon gas as the condensation medium were used in the ELGC method. The best process parameters for the synthesis of aluminum nanoparticles were determined.
Funded by:
Team Members:
the electromagnetic levitation melting was performed by Okress et al. in 1952, this process has recently been introduced as a promising method for the synthesis of nanoparticles. Among all the other production methods of nanoparticles, this method can result in a much higher production rate and a lower level of contamination.
Due to the difficulty in the levitation melting of alloys, no extensive works have been reported so far on the use of this technology
for different nanomaterials. In the present work, a novel electromagnetic levitational gas condensation (ELGC) system was designed and manufactured for the synthesis of aluminum nanoparticles. Pure aluminum as the charge metal and argon gas as the condensation medium were used in the ELGC method. The best process parameters for the synthesis of aluminum nanoparticles were determined.
Funded by:
- Isfahan University of Technology
Team Members:
- Assoc. Prof. Ahmad Kermanpur (Supervisor)
- Ehsan Ghasselai (Bachelor student)
- Saman Salemizadeh (Bachelor student)
