High solid loading aqueous base metal/ceramic feedstock for injection molding

Increasing volume fraction of metal powder in feedstock provided lower shrinkage. Reduction of the shrinkage results in better dimensional precision. The rheology of the feedstock material plays an important role to allowing larger volume fractions of the metal powder to be incorporated in the feedstock forinulations. The viscosity of the feedstock inainly depends on the binder viscosity, powder volume fraction and characteristics of metal powder. Aqueous polysaccharide agar was used as a baseline binder system for this study.The effect of several gel-strengthening additives on 1.5wt% and 2wt% agar gel was evaluated. A new gel-strengthening additive was found to be the most effective among the others. The effect of other additives such as glucose, sucrose and fructose on viscosity of baseline binder and feedstock was investigated. Two new agar based binder compositions were developed. The use of these new binder forinulations significantly improved the volume fraction of the metal powder, the stability of the feedstock, and reduced the final shrinkage of the molded articles. Two types of 17-4PH stainless steel metal powders, one gas atomized and, the other water atomized, were used for this research

Solid Freeform Fabrication of Stainless Steel Using Fab@Home

Metal or ceramic parts can be solid freeform fabricated (SFF) using powdered material processing techniques. A slurry of the powdered material is deposited in a layer-by-layer fashion, and then sintered. We demonstrate this process using a 17-4 PH stainless steel slurry deposited via robotically controlled syringe in the low-cost Fab@Home rapid prototyper. Completed parts had densities as high as 90% volume fraction and tensile strength as high as 35% of the pure solid. Details of the process as well as a number of samples of different geometries are shown.Mechanical Engineerin

Bidding strategy for a virtual power plant for trading energy in the wholesale electricity market

Virtual power plants (VPPs) are an effective way to increase renewable integration. In this PhD research, the concept design and the detailed costs and benefits of implementing a realistic VPP in Western Australia (WA), comprising 67 dwellings, are developed. The VPP is designed to integrate and coordinate an 810kW rooftop solar PV farm, 350kW/700kWh vanadium redox flow batteries (VRFB), heat pump hot water systems (HWSs), and smart appliances through demand management mechanisms. This research develops a robust bidding strategy for the VPP to participate in both load following ancillary service (LFAS) and energy market in the wholesale electricity market in WA considering the uncertainties associated with PV generation and electricity market prices. Using this strategy, the payback period can be improved by 3 years (to a payback period of 6 years) and the internal rate of return (IRR) by 7.5% (to an IRR of 18%) by participating in both markets. The daily average error of the proposed robust method is 2.7% over one year when compared with a robust mathematical method. The computational effort is 0.66 sec for 365 runs for the proposed method compared to 947.10 sec for the robust mathematical method. To engage customers in the demand management schemes by the VPP owner, the gamified approach is adopted to make the exercise enjoyable while not compromising their comfort levels. Seven gamified applications are examined using a developed methodology based on Kim’s model and Fogg’s model, and the most suitable one is determined. The simulation results show that gamification can improve the payback period by 1 to 2 months for the VPP owner. Furthermore, an efficient and fog-based monitoring and control platform is proposed for the VPP to be flexible, scalable, secure, and cost-effective to realise the full capabilities and profitability of the VPP