In this thesis the finite element computer code QUEANA simulating the quenching of axisymetric parts and determining the residual stress state was improved by adding pre- and post-processors. The code was further verified by additional numerical experiments and comparison of the results with commercial software &ldquo / MARC&rdquo / . The possible applications of this code are optimization of industrial quenching processes by controlling the evolution of internal stresses and dimensional changes.

Due to the environmental issues related with fuel consumption and additionally passenger safety, aluminum space frame chassis is promising a big opportunity to design a lightweight structure with a high stiffness. Despite the lower stiffness and strength of aluminum in comparison to the conventional steel chassis, it can be compensated with changing thickness and design of structure by space frame geometry In this study, instead of using steel for automobile chassis, main goal is producing a space frame structure with using aluminum in an extrusion and sand casting processes and improve the stiffness. Chassis is designed according to calculations for moment of inertia, torsional and bending stiffness and in sufficient structural stiffness which can compete with steel chassis. Static finite element analysis was carried out to understand the chassis bending, torsional stiffness and fatigue behaviors. For frontal collisions, dynamic finite element analysis was also done to determine increases in the energy absorbance, specific energy absorbance and peak force for passenger safety. Aluminum profiles were produced by hot extrusion and joined with sand casting parts by TIG welding to manufacture a space frame structure. For main chassis profile, 6063 series of aluminum alloy was selected due to availability for extrusion process, weldability and having sufficient tensile strength and percent elongation and treatment response. Three point bending test was carried out to determine flexural strength. Moment of inertia calculations were done. Some parts such as side frame and shock absorber tower were produced by sand casting method. A similar composition to Silafont &ndash / 36 aluminum alloy was selected because of its high fluidity and good mechanical properties / despite it is a die cast alloy. Tensile, hardness and Charpy impact test were conducted to determine the mechanical characteristics of Silafont - 36 sand cast alloy. In addition to microstructure features and thermal analysis were also carried out to achieve sufficient alloy properties. Heat affected z one was investigated by hardness and tensile test to determine the mechanical properties change after welding process. In this space frame development study, A, B and C pillar parts were produced by Al &ndash / Si sand casting and T6 heat treatment then welded together by TIG welding and finally assembled on the bottom chassis frame produced by using 6063 extrudes welded by 4000 series electrodes. The space frame chassis was studied by also computer simulation to test and see critical points which must be modified during manufacturing. Besides the experimental and theoretical studies, space frame was also produced at the same time. According to the experimental results, the feasibility of the production of lightweight and solid chassis structure was achieved.

In the scope of this study, TiNi foams with porosities in the range of 39-64 vol% were processed from prealloyed powders by Mg space holder technique. Porous TiNi alloys displayed homogeneously distributed spherical pores with interconnections, which is suitable for bone ingrowth. Porous Ti-50.8 at%Ni alloys were processed by sintering at 1200 &deg / C for 2 h to analyze the microstructure as well as mechanical behavior. SEM, TEM and XRD studies were conducted for the characterization of microstructure and phase analyses in addition to the mechanical characterization performed by monotonic and superelasticity compression tests as well as compressive fatigue tests. It was observed that stress required to trigger martensitic transformation was decreased via increasing porosity. The monotonic compression test results also indicated that altering the porosity content of TiNi foams leads to different monotonic compression behaviors. It was observed that the foams display more bulk deformation like behavior as a composite structure composed of TiNi and macropores when the porosity content was low. As the porosity content has increased, the struts became more effective and deformation proceeds by the collapse of favorable struts. On the other hand, cyclic superelasticity tests results indicated that maximum achieved and recovered strain values at the end of fifth cycle increase while the fraction of strain recovered at the end of fifth cycle decreases with decreasing porosity content. Furthermore, the fatigue lives of the processed foams were observed to vary within a band which has a width decreasing with decreasing &sigma / max / &sigma / y yielding an endurance limit ranging in between 26-89 MPa or 0.5-0.6 &sigma / y. Fractography studies on the failed foams after fatigue testing revealed that the failure occurs by the coalescence of micro-cracks initiated from pore walls leading to macro-cracks aligned at 45o with respect to the loading axis. In addition to the mentioned characterization studies, the effects of sintering temperature and time on TiNi foams with 58 vol% porosity as well as heat treatment on the microstructure and the mechanical behavior of TiNi foams with 49 vol% porosity were analyzed with SEM and compression tests. Aging of TiNi foams with 49 vol% porosity at 450 &deg / C for 1.5 h has shown that the presence of Ti3Ni4 precipitates improve the superelastic response.

Joining of electronic components onto the circuit boards is done by soldering operation, during production of all electronic devices. In many countries, including Turkey, traditionally used tin-lead (Sn-Pb) solder alloys have been restricted to be used in consumer electronics appliances because of the toxic effects of lead (Pb) within these alloys. Tin-silver-copper (Sn-Ag-Cu) based alloys have been developed as the most promising candidate that can replace the Sn-Pb alloys. However, various problems have emerged with the increasing trend in use of Sn-Ag-Cu solder alloys in electronics industry, namely large intermetallic compound formation, low wettability and thermal shock resistance. Many researches have been done in the past decade to overcome these problems. The solutions are based on changing the undercooling of the solder alloy / which was determined to be done by either changing the composition of the solder alloy by micro-alloying or changing the cooling rate during soldering operation. In this thesis study Sn-3.5Ag-0.9Cu (wt. %) lead-free solder having the eutectic composition, was micro-alloyed with additions of aluminum (Al), iron (Fe) and titanium (Ti). Experimental results were compared with commercially available near-eutectic Sn-40Pb (wt. %) solder, a commercially available Sn-3.0Ag-0.5Cu (wt. %) solder and also eutectic Sn-3.5Ag.0.9Cu (wt. %) and near-eutectic Sn-3.7Ag-0.9Cu (wt. %) solders that were produced for this thesis study. In the first stage of the study, the effects of 0.05 wt. % of Al, Fe and Ti micro-alloying were investigated. When preliminary results of mechanical and thermal test were compared, Fe was found to make positive effect on shear strength and undercooling. Further research was carried out to establish a relationship between the Fe compositions and solder properties. Therefore, 0.01, 0.03, 0.07 and 0.1 wt. % Fe additions were also studied and results were reported. 0.01 wt. % and 0.07 wt. % Fe added solders were found to have a smaller undercooling, resulting with dispersed intermetallic compound (IMC) and thus has highest shear strength. Different cooling rates / 0.017, 0.17 and 1.7 &deg / C/sec were applied to solder-copper joints and microstructures were investigated. Large IMC-free microstructure was achieved by 0.01 wt. % Fe micro-alloyed solder, which was cooled with 1.7 &deg / C/sec rate. Wetting of copper substrate was found to be improved by additions of Al, Fe and Ti compared to alloy with eutectic composition of Sn-Ag-Cu alloy. Selected SAC+X alloys have been subjected to thermal shock experiments for crack formation analysis on the copper substrate-solder joints. The results showed that SAC+0.05Al solder has the higher thermal shock resistance, which no cracks were observed after 1500 cycles of thermal shock. In order to understand the insights of SAC performance, some of the lead-free solders were applied onto printed circuit boards for thermal shock resistance test. These results have indicate that the cracking may occur after thermal shock cycles due to process conditions of soldering operation (i.e. cooing rate), independent of the solder alloy composition.

Copper losses to slag are generally between 0.7-2.3% during the copper matte smelting stage. In this study, the aim was to reduce these losses in the slag phase. For this purpose, usage of some additives (especially calcined colemanite labeled as CC, boric oxide-B2O3 and calcium oxide-CaO as well) as flux material was investigated. The flash furnace matte-slag (FFM-FFS) obtained from Eti Copper Inc. and a master matte-slag (MM-MS) produced synthetically were used as starting materials. Additives were tested in various amounts under two different atmospheres (N2 and low Po2 obtained by mixture of CO2/CO gases). Temperature and duration were also used as experimental variables. Experimental results have indicated that 2 hours was sufficient to obtain a low copper content in slag about 0.3% and 0.4% for FFS and MS, respectively. It was also seen that the copper content in slag decreased with increasing CC addition at all oxygen partial pressures and at all temperatures. Furthermore, the addition of all additives up to 4% had great influence in lowering the copper content in the final slags (~0.3%Cu). From FactSage calculations, it could be concluded that the colemanite addition decreased the liquidus temperature which led to early melting of slag and allowed enough duration for settling of matte particles within the slag without substantial changing its viscosity, which resulted in less mechanical copper losses to the slag. By using colemanite in copper production, it was possible that a new application area for boron compounds which are produced in Turkey could be created.

In this thesis work, a high grade chromite concentrate obtained from PinarbaSi, Kayseri region of Turkey was reacted with sulfuric acid solution to determine the optimum conditions of leaching of chromite ores. Conventional methods for producing chromium are still valid in industry. The main process in production includes soda melting and taking it into solution in the form of chemical compounds such as sodium dichromate. Three and six valence states of chromium have importance in production. Trivalent chromium, chrome ore or chromite have no harmful effects. However, compounds of hexavalent chromium show toxic, irritating and corrosive action to people and environment. In the mentioned conventional method, main products consist of hexavalent chromium compounds. In this study, only trivalent chromium remained in the leach solution and did not change to hexavalent state. Obtained product after leaching was chromium(III) sulfate. The maximum extraction of chromium in the absence of perchloric acid was 94.1 % under the conditions of 175 &deg / C, 6 hours and 84.6 wt % sulfuric acid. The maximum extraction of chromium in the presence of perchloric acid was 98.7 % under the conditions of 175 &deg / C, 2 hours, 84.6 wt % sulfuric acid and &frac12 / perchloric acid / chromite ratio. The latter one was also the highest recovery value obtained during the experiments. Moreover, in none of the analyzed samples, appreciable amounts of hexavalent chromium was found during analyses.

Main reason for the current losses in electrolytic magnesium production is the reaction between electrode products. Present study was devoted to effective separation of chlorine gas from the electrolysis environment by a new cell design and thus reducing the extent of back reaction between magnesium and chlorine to decrease energy consumption values. The new cell design was tested by changing temperature, cathode surface, current density, anode cathode distance and electrolyte composition. Both the voltages and the current efficiencies were considered to be influenced by the amount and hydrodynamics of chlorine bubbles in inter-electrode region. Cell voltages were also found to be affected from the nucleation of magnesium droplets and changes in electrolyte composition that took place during the electrolysis. A hydrodynamic model was used to calculate net cell voltage by including the resistance of chlorine bubbles on anode surface to theoretical decomposition voltage during electrolysis. Good correlations were obtained between experimental and calculated voltages. The same model was used to calculate current efficiencies by considering chlorine diffusion from bubble surfaces. A general agreement was obtained between calculated and experimental current efficiencies. Desired magnesium deposition morphology and detachment characteristics from cathode were obtained when MgCl2-NaCl-KCl-CaCl2 electrolytes were employed. Current efficiencies higher than 90% could be achieved using the above electrolyte. The cell consumes around 8 kWh&amp / #903 / kg-1 Mg at 0.43 A&amp / #903 / cm-2 as a result of high chlorine removal efficiency and capability of working at low inter-electrode distances. Furthermore, the cell was capable of producing magnesium with less than the lowest energy consumption industrially obtained, at about double the commonly practiced industrial current density levels.

In the present study / the effects of the powder metallurgical parameters such as the mixing method, compaction pressure, initial tungsten (W) particle size, composition, sintering temperature and sintering time on the sintering behavior of selected high density W-Ni-Cu alloys were investigated. The alloys were produced through conventional powder metallurgy route of mixing, cold compaction and sintering. The total solute (Ni-Cu) content in the produced alloys was kept constant at 10 wt%, while the copper concentration of the solutes was varied from 2.5 wt% to 10 wt%. Mainly liquid phase sintering method was applied in the production of the alloys. The results of the study were based on the density measurements, microstructural characterizations including optical and scanning electron microscopy and mechanical characterizations including hardness measurements. The results showed that the nature of the mixing method applied in the preparation of the powder mixtures has a considerable effect on the final sintered state of W-Ni-Cu alloys. Within the experimental limits of the study, the compaction v pressure and initial W particle size did not seem to affect the densification behavior. It was found that the sintering behavior of W-Ni-Cu alloys investigated in this study was essentially dominated by the Ni content in the alloy and the sintering temperature. A high degree of densification was observed in these alloys with an increase in the Ni content and sintering temperature which was suggested to be due to an increase in the solubility and diffusivity of W in the binder matrix phase with an increase in these parameters, leading to an increase in the overall sintering kinetics. Based on the results obtained in the present study, a model explaining the kinetics of the diffusional processes governing the densification and coarsening behavior of W-Ni-Cu alloys was proposed.

The aim of this work is to nondestructively characterize the industrial dual phase (ferritic-martensitic) steels (DPS) by the Magnetic Barkhausen Noise (MBN) method. By quenching of AISI 8620 steel specimens having two different starting microstructures, from various intercritical annealing temperatures (ICAT) in the ferrite-austenite region, the microstructures consisting of different volume fractions of martensite and morphology have been obtained. The microstructures, strength properties and hardness values were determined by conventional metallographic and mechanical tests. The measurements of the Magnetic Barkhausen Noise (MBN) were performed by using both Rollscan and &amp / #956 / SCAN sensor connectors. A good correlation between the martensite volume fraction, hardness and MBN signal amplitude has been obtained. MBN emission decreased as the ICAT, therefore the volume fraction of martensite increased. Moreover, MBN emission decreased as the martensite morphology become thinner. It has been concluded that MBN method can be used for nondestructive characterization of industrial dual phase steels.

With constant miniaturization of integrated circuits, the current densities experienced in interconnects in electronic circuits has been multiplied. Aluminum, which is widely used as an interconnect material, has fast diffusion kinetics under low temperatures. Unfortunately, the combination of high current density and fast diffusion at low temperatures causes the circuit to fail by electromigration (EM), which is the mass transport of atoms due to the momentum transfer between conducting electrons and diffusing atoms. In the present study, the effect of alloying elements in aluminum on the diffusion behavior is investigated using a non equilibrium molecular dynamics method (NEMD) under the effect of electromigration wind force. The electromigration force was computed by the use of a pseudopotential method in which the force depends on the imperfections on the lattice. 1.125 at% of various elements, namely Cu, Mg, Mn, Sn and Ti were added into aluminum. The electromigration force was then calculated on the alloying elements and the surrounding aluminum atoms and these forces incorporated into molecular dynamics using the non-equilibrium formalism. The jump frequencies of aluminum in these systems were then computed. Cu, Mn and Sn impurities were found to be very effective in lowering the kinetics of the diffusion under electromigration conditions. Cu was known experimentally to have such an effect on aluminum for several years, but the Mn and Sn elements are shown here for the first time that they can have a similar effect.