Les pièces de structure aéronautique utilisées dans l’aéronautique sont fabriquées en plusieurs étapes. Des étapes, comme le traitement thermique, génèrent des contraintes résiduelles. Les enlèvements de matière réalisés par les opérations d’usinage peuvent alors conduire à la réorganisation des contraintes résiduelles dans la matière et ainsi à la déformation de la pièce. La mesure in-situ de ces déformations devient nécessaire lorsque ce phénomène est étudié. Ces travaux de thèse abordent cette problématique dans le cadre du projet SIMP-Aero. L’objectif de ces travaux de thèse est d’adapter la méthode de corrélation d’images numériques à la mesure de la déformation de pièce pendant l’usinage, c’est-à-dire dans un centre d’usinage. Pour cela, plusieurs améliorations sont apportées à la méthode. Premièrement, les mouvements du système optique sont pris en compte afin que ceux-ci n’altère pas la qualité des mesures. Ensuite, les copeaux présents sur les images sont détectés et filtrés par un algorithme. Au final, la méthode développée permet de mesurer des champs de déplacement durant toute la séquence d’usinage, sans devoir l’interrompre, avec une incertitude de mesure de l’ordre du centième de millimètre. / Structural aluminum alloy parts used in aeronautics are manufactured in several steps, from forming processes and heat treatments to final machining. Some of the process steps induce residual stresses. The material removal during machining release these residual stresses and thus, leads to the part deformation. The in-situ measurement of these deformations becomes necessary when this phenomenon is studied. The present work address this problematic in the context of the ANR SIMP-Aero Project. It aims to define a reliable experimental technique dedicated to the measurement of part deformations during machining of large aeronautical parts. The backbone of the technique relies on Digital Image Correlation (DIC). Mainly as a consequence of the harsh constraints environment of machining, the customization of DIC is required. First, movements of the optical system are quantified and compensated for the proper measurement of the workpiece displacement. Then, the metal chips that fly between the observed surface and the acquisition system are detected and filtered by the algorithm. Finally, the developed method enables the measurement of displacement fields throughout the whole machining sequence, without interrupting it, and a measurement uncertainty of around one hundredth of a millimeter is ensured.

Digital Image Correlation (DIC) is a technique which uses images taken before and after deformation to determine displacement and strain data over the surface of the sample. In order to obtain this data for both in-plane as well as out-of-plane direction, multiple views of the sample are required. Typically, this is accomplished using multiple cameras, but it is possible to use diffraction gratings to bend the light coming from the specimen in order to allow a single camera to capture multiple views. This technique is referred to as Diffraction Assisted Image Correlation (DAIC) and has been previously demonstrated at room temperature. This work expands this method for use at high temperatures by incorporating the use of ultraviolet (UV) lights for illumination and filtering out the light in the visible spectrum. This increases the temperature at which useful images can be captured by reducing the glow that specimens produce at elevated temperatures. When not filtered out, this glow saturates the camera sensor making DIC impossible. This new technique is referred to as Ultraviolet Diffraction Assisted Image Correlation (UV-DAIC).

Les propriétés mécaniques des alliages de fer sont largement conditionnées par leur microstructure et la population de défauts locaux qu’elle contient. Comme il s'agit d'un moment de forte interaction entre ces deux éléments, l'étude des transformations α-γ et γ-α du fer mérite une attention particulière. Outre le passage d'une structure cristalline cubique centrée à une structure cubique faces centrées – donc de compacités différentes –,elles sont associées à une réduction des paramètres de maille. Le changement de volume correspondant est responsable de déformations mécaniques locales autour des sites de germination. La technique de corrélation d'images numériques(CIN) s'est montrée fiable pour ce qui est de calculer des champs cinématiques à l'échelle de quelques grains. Dans ce travail, elle est adaptée à la capture de localisations de la déformation pendant les transformations allotropiques. Un banc expérimental est conçu pour obtenir des images haute résolution avec un contrôle fin des sollicitations thermiques. Des essais de validation sont d'abord effectués sur du fer industriel. Puis des échantillons de fer haute pureté sont ensuite soumis à des cycles de transformation α-γ-α et les champs de déformation correspondant sont calculés par CIN. Associés à l'acquisition des orientations initiales et finales, ils sont utilisés pour valider les mécanismes de transformation proposés dans la littérature. En parallèle, un modèle, écrit en petites déformations, est construit en incorporant des composants liés à la transformation dans une fonctionnelle dont les conditions de stationnarité sont équivalentes au problème thermomécanique à résoudre. Les incréments des variables internes, incluant glissements plastiques et fractions volumique transformées, sont obtenus en minimisant cette fonctionnelle. / Mechanical properties of iron-based alloys are largely conditioned by their microstructure and the population of local defects inside this microstructure. As it is a moment of massive interplay between these two elements, the study of the α-γ and γ-α transformations in iron is of particular interest. Besides a change from a body-centered cubic to a face-centered cubic crystal structure – and thus a change in compacity –, they lead to a lattice parameter reduction. The corresponding change in volume is responsible for local mechanical deformations around transformation sites. Digital Image Correlation (DIC) technique has been proven reliable to compute kinematic fields at the scale of a few grains. In the present work, an adaptation of this technique to the observation of strain localizations induced by the formation of a new phase is proposed. A home-made device is designed to obtain high resolution images and to control heating and cooling. Tests are first conducted on industrial iron to assess the viability of the procedure. High-purity iron samples are then submitted to α-γ-α transformation cycles and the associated strain fields are computed. In combination with the acquisition of initial and final orientations they are used to validate transformation mechanisms proposed in the literature. In parallel, a model, written under the small strain format, is built by incorporating transformation related components into a power functional whose stationarity conditions are equivalent to the thermomechanical problem. In accordance with variational principles, the evolution of internal variables,including plastic slip increments and fraction of the material locally transformed, are computed through the minimization of the functional.

Chaque année, d'innombrables collisions se produisent entre des avions en vol et des oiseaux. L'impact aviaire, menace redoutée par les pilotes, concerne tant l'aviation civile que son pendant militaire. Les statistiques démontrent que, même si fort heureusement le nombre d'accidents graves reste limité, les incidents sont de plus en plus nombreux. Parmi les acteurs qui luttent contre ce danger, les constructeurs d'avions jouent un rôle prépondérant. Contraints par des réglementations internationales, ils s'attachent à produire des éléments de structure qui résistent à l'impact d'oiseaux. Dans la mise au point de leur produits, les avionneurs démontrent cette résistance à l'aide d'essais d'impact : on accélère un simulant d'oiseau jusqu'à la vitesse voulue -- de l'ordre de la vitesse de croisière nominale de l'avion -- et on le projette sur un aileron ou un morceau de fuselage. La présente thèse doctorale, co-dirigée par les professeurs Philippe Bouillard de l'ULB et Marc Pirlot de l'ERM, contribue doublement à l'amélioration de ces techniques d'essais dynamiques. D'une part, elle réalise la mise au point et la validation d'un lanceur pyrotechnique à double étage pour l'accélération du simulant d'oiseau. Un canon de calibre 20 mm est combiné avec un accélérateur de calibre 160 mm. La combustion d'un mélange de poudre propulsive contenu dans une douille adaptée génère les gaz à haute température et à haute pression nécessaires à l'accélération d'un simulant d'oiseau dûment confiné dans un conteneur de protection. Un dispositif de séparation arrête le conteneur afin que seul le simulant d'oiseau percute l'élément d'avion à l'essai. La solution pyrotechnique à double étage mise au point est validée par de nombreux tirs instrumentés en vitesse, en accélération et en pression ; elle se révèle conforme aux exigences de sécurité et de reproductibilité. Le lanceur pyrotechnique présente par rapport aux solutions pneumatiques, utilisées à notre connaissance dans tous les autres centres d'essais, des avantages indéniables de compacité ainsi que de rapidité et de souplesse de mise en oeuvre. D'autre part, la migration des alliages métalliques vers les matériaux composites est amorcée depuis plusieurs années déjà dans le monde de la construction aéronautique. Pour optimiser les structures, une connaissance des caractéristiques de ces matériaux est indispensable. Les modes de rupture font partie des caractéristiques encore mal connues. La mesure du déplacement hors-plan lors du tir sur panneaux plans est une des manières de quantifier le comportement du matériau sous l'action d'un impact. Cette mesure s'opère généralement de manière statique, après le tir. Une méthode de mesure dynamique a été mise au point, basée sur l'emploi de techniques de stéréoscopie par corrélation numérique d'images. Cette technique a été validée au moyen d'une méthode métrologique indépendante d'extensométrie laser. ABSTRACT Countless collisions occur each year between airplanes and birds. Bird strike is a concern to both civilian and militay aircraft. Statistics show that, although the number of serious accidents fortunately remains low, the number of incidents keeps increasing. Amongst the actors tackling this issue, aircraft manufacturers play an important role. In compliance with international regulations, they have to produce structural elements that withstand bird impact. During the development of their products, aircraft manufacturers have to demonstrate this resistance through bird impact trials : a bird surrogate is accelerated to the required velocity - often close to the nominal cruise speed of the aircraft - and launched onto a flap or a piece of fuselage. This PhD thesis has been co-supervised by Professor Philippe Bouillard (ULB) and Professor Marc Pirlot (ERM-KMS). Its contribution to the improvement of the aforementioned dynamic trials is twofold. One one hand, a two-stage pyrotechnical launcher for bird surrogates has been developed and assessed. A 20 mm caliber gun is connected to a 160 mm diameter launcher. The combustion of a propellant mixture in a cartridge case generates high pressure, high temperature gases which accelerate a bird surrogate protected by a cylindrical container. A stripper refrains the container from hitting the target pane. The pyrotechnical solution has been assessed through an important number of firings where pressure, velocity and acceleration have been measured. The solution has proven compliance with both the safety requirements and the repeatability specifications. Its advantages compared to the pneumatic solutions used, as far as we know, in all other test centres, include compactedness as well as flexibility and high firing rate. On the other hand, migration towards composite materials has been initiated years ago in the area of aeronautical constructions. To optimize structures, a thorough knowledge of these new materials is required. Failure modes belong to the still badly known features of carbon reinforced plastics. Measuring the out-of-plane deformation when firing on a flat pane is one way of quantifying the material's behaviour under impact. This measurement is most frequently made in a static way, after completion of the firing. A dynamic measuring method has been developed, based upon stereoscopic digital image correlation techniques. This technique has been validated by means of an independent laser extensometer measuring method.

Commercially available polycrystalline Ni (Ni200; grain size: 32 μm) and electrodeposited nanocrystalline Ni (grain size: 57 nm), Ni-2.6%Fe (grain size: 25 nm) and Ni-8.5%Fe (grain size: 20 nm) were analyzed for the phenomena of stress-induced heat generation and strain localization during plastic deformation at room temperature (i.e. 250C). Tensile specimens according to ASTM E8 standard dimensions were tested at strain rates of 10-2/s and 10-1/s, respectively, to record the amount of heat dissipated and the change of localized strain using a high resolution infrared (IR) detector and digital image correlation (DIC) camera, respectively. Results have shown that the maximum temperatures that were recorded in nanocrystalline Ni and Ni-Fe alloys were at least 300C lower than the onset temperatures for subgrain coalescence previously measured through differential scanning calorimetry. It can be concluded that thermally activated grain growth during tensile testing of nanocrystalline Ni and Ni-Fe alloys is not likely to occur.

Commercially available polycrystalline Ni (Ni200; grain size: 32 μm) and electrodeposited nanocrystalline Ni (grain size: 57 nm), Ni-2.6%Fe (grain size: 25 nm) and Ni-8.5%Fe (grain size: 20 nm) were analyzed for the phenomena of stress-induced heat generation and strain localization during plastic deformation at room temperature (i.e. 250C). Tensile specimens according to ASTM E8 standard dimensions were tested at strain rates of 10-2/s and 10-1/s, respectively, to record the amount of heat dissipated and the change of localized strain using a high resolution infrared (IR) detector and digital image correlation (DIC) camera, respectively. Results have shown that the maximum temperatures that were recorded in nanocrystalline Ni and Ni-Fe alloys were at least 300C lower than the onset temperatures for subgrain coalescence previously measured through differential scanning calorimetry. It can be concluded that thermally activated grain growth during tensile testing of nanocrystalline Ni and Ni-Fe alloys is not likely to occur.

In this studing, application of the digital image correlation method (DIC) for determining the coefficient of thermal expansion (CTE) of Indium Tin Oxide/Polyethylene Terephthalate(ITO/PET) thin film/flexible substrate was proposed and the effects of thinkness variations of ITO and PET, respectively, on the CTE of the specimens was disscussed. The observation range of experimental temperature was chosen from room temperature to the glass transfer temperature of PET, 70¢J. A novel DIC experimental process for reducing the errors caused from the variations of the refractive index of the surrounding heated air was proposed. As a result, the experimental error of CTE measurement was reduced form 10~17% to less than 5%. The experimental results showed that the CTE of ITO/PET specimen is anisotropic. Futhermore, the CTE of an ITO/PET specimen will be increased by decreasing the thinkness of PET flexible substrate, and increased by increasing the thinkness of ITO film - which means decreasing the surface resistance of ITO film.

Amorphous polymers under their glass transition temperature (Tg) exhibit large inelastic deformations. Their mechanical behavior is highly dependent upon temperature, strain rate, pressure and loading mode (tension, compression, shear). They also exhibit small strain isotropic hardening, softening and large strain anisotropic rehardening. In addition, while in their glassy state, polymers are far from thermodynamic equilibrium so that their properties may change over time (physical aging). This complex behavior is reflected in the response of composites and affects the onset and propagation of damage therein. Therefore, in order to design polymer composite structures, it is fundamental to develop relevant tools and methodologies which aim at understanding, capturing and predicting the full thermomechanical response of glassy polymers. In this study, the thermomechanical behavior of a thermosetting polymer epoxy is characterized experimentally for temperatures below Tg. The intrinsic behavior of the polymer is obtained using a new methodology based on digital image correlation (DIC) in combination with video-monitored extensometry. In particular, inelastic flow localization patterns are discussed based on the full-field strain measurements and their connection to the stress-strain curves are highlighted. The Boyce-Parks-Argon polymer constitutive model, hereafter called the macromolecular model, has been enhanced to describe the thermomechanical behavior of epoxies. The identification of the material parameters involved in the model is described in a detailed procedure that builds on a limited set of experiments. The model is shown to represent adequately the thermomechanical behavior of the studied epoxy over a wide range of temperatures and strain-rates. Using additional high strain-rate data obtained from collaborators on Kolsky bars, the model capabilities are further discussed. Using finite-element implementations of the constitutive model in both quasi-static and dynamic codes, the processes of plastic flow localization are analyzed in tensile and compression specimens. Such analysis can form the basis of an alternative method for identifying the model parameters through inverse identification. Finally, a preliminary set of experiments were also conducted to investigate the effect of physical aging on the yield behavior and enhance the macromolecular model with the capability of modeling aging effects. Our interpretation of the aging experiments suggests that they are not conclusive and do not permit full determination of model parameters. Specific recommendations are tentatively formulated for conducting aging experiments in the future.

In this study, a simple and inexpensive membrane mechanical property measuring system was developed. By applying the force on a membrane and recording the corresponding out-of-plane displacement fields, then the Young¡¦s modules and Possion¡¦s ratio of the membrane can be obtained from those deformations through the inverse approach. Firstly, a loading frame was designed to fix the membrane and allow the membrane can be loaded and its deformations can be measured precisely. In order to measure the out-of-plane displacement fields of the loaded membrane, the digital image correlation (DIC) was used and an easier 3-D DIC measuring method was proposed in this study. The proposed 3-D DIC measuring method was verified by using a loaded cantilever beam with ESPI. The error was within in 10%. In this study, the smallest in-plane displacement that can be measured by proposed method is 2 £gm and the smallest out-of-plane displacement that that can be measured is 6£gm. In this study, in order to determine the mechanical properties of the membrane, digital image correlation, finite element method (FEM) and optimization method were combined with the measured out-of-plane displacement fields, then the Young¡¦s modules and Possion¡¦s ratio of the membrane were determined through the inverse approach. The FEM simulations were performed by using ANSYS. Several optimization theorems were adopted and their corresponding merits on this study were compared The obtained Young's modulus was compared with the results obtain from the nano-indentor and the error was within in 3% ~ 12%. Keyword: digital image correlation, membrane, Young¡¦s modules, Possion¡¦s ratio, finite element method, optimization method.

The bulge test is a commonly used experiment to establish the material stress-strain response at the highest possible strain levels. It consists of a metal sheet placed in a die with a circular opening. It is clamped in place and inflated with hydraulic pressure. In this thesis, a bulge testing apparatus was designed, fabricated, calibrated and used to measure the stress-strain response of an aluminum sheet metal and establish its onset of failure. The custom design incorporates a draw-bead for clamping the plate. A closed loop controlled servohydraulic pressurization system consisting of a pressure booster is used to pressurize the specimens. Deformations of the bulge are monitored with a 3D digital image correlation (DIC) system. Bulging experiments on 0.040 in thick Al-2024-T3 sheets were successfully performed. The 3D nature of the DIC enables simultaneous estimates of local strains as well as the local radius of curvature. The successful performance of the tests required careful design of the draw-bead clamping arrangement. Experiments on four plates are presented, three of which burst in the test section as expected. Finite deformation isotropic plasticity was used to extract the true equivalent stress-strain responses from each specimen. The bulge test results correlated well with the uniaxial results as they tended to fall between tensile test results in the rolling and transverse directions. The bulge tests results extended the stress-strain response to strain levels of the order of 40%, as opposed to failure strains of the order of 10% for the tensile tests. Three-dimensional shell and solid models were used to investigate the onset of localization that precedes failure. In both models, the calculated pressure-deformation responses were found to be in reasonable agreement with the measured ones. The solid element model was shown to better capture the localization and its evolution. The corresponding pressure maximum was shown to be imperfection sensitive. / text