Development of a length scale engineered high pressure injection manifold

  • Chuan Jie Wong

    Student thesis: Doctoral ThesisDoctor of Philosophy

    Abstract

    The strength of a material is a key design parameter that has to be predicted or simulated in the design of all manufactured components. For metals, material strength is mainly determined by microstructural length scales, which affect how easily dislocations can move in the material. Strength can be manipulated by changing the length scale of the material. Nano-technology is opening up opportunities for large reductions in material length-scales and correspondingly large strength increases. Such “Length-scale engineering” offers manufacturers stronger, lighter, more sustainable components. New industrial impact opportunities are available, therefore, for companies with the ability to manufacture nano-scale materials in volume, in an economic and sustainable way, to create components with a length-scale enabled design.

    This project has developed a novel 3D additive deposition method with the ability to reduce material length scales to the nano-micro range. The new process offers a step change in energy and waste reduction, reduces assembly costs by enabling single piece manufacture and has the potential for continuous recyclable production. The method enables the deposition of nano/micro scale copper (a grain size of less than 200 nm), whose strength is over 2.8 times greater than generic industrial copper, which exceeds the strength of the ASI 304 stainless steel that is used in automotive common rail fuel injection manifolds. The project has generated a proof of concept three-way manifold with integrated fittings and demonstrated the ability to manufacture bespoke shapes that are difficult or impossible to manufacture by conventional machining. The project evaluates the Technology Readiness Level (TRL) to have been raised to level 5 and ready for the development of prototype components to be used in field trials to enhance their attractiveness for adoption of the manufacturing process by large end-users.
    Date of Award2020
    Original languageEnglish
    Awarding Institution
    • Coventry University
    SupervisorNigel Jennett (Supervisor)

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