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)
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)
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 (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)
