<p>With the emergence of additive manufacturing (AM), there is a need to understand the role of microstructures resulting from AM on the mechanical performance of the material. Ti-6Al-4V alloys are widely used within the aerospace industry as well as other industries to achieve high strength, low weight premium performance parts. There is a desire to utilize AM to produce Ti-6Al-4V, although these materials need to be qualified prior to their use in safety critical applications. Within the qualification of AM Ti-6Al-4V in aeronautics, fatigue loading is a crucial aspect to. It has been seen that within AM Ti-6Al-4V, prior β boundaries can be locations of microscopic localization of plastic strain which often lead to fatigue crack initiation. This thesis aims to further understand and predict the role of AM Ti-6Al-4V microstructures in dictating fatigue behavior. Specifically, the goal was to gauge the contributions of two microstructural features resulting from AM, prior β boundaries and α lathe-shaped grains, to the localization behavior. With the need to understand and predict the emergent behavior of the material system, crystal plasticity finite element (CPFE) methods were used in this thesis as the main method. </p> <p><br></p> <p>Within the context of CPFE, there is an existing gap in the current literature of realistic synthetic microstructures of Ti-6Al-4V that capture both the prior β boundaries and α lathes. With the ability to generate realistic FE models, the effects of the microstructural features can be better studied and characterized. The first portion of this thesis focuses on the generation of such synthetic microstructures which are simulated within the CPFE framework. An emphasis is placed on modeling the prior β boundaries and α grains. As these generated models are statistically equivalent to actual microstructures, material characterization via EBSD was performed on specimen that were used in the experimental fatigue testing. With the framework’s ability to generate synthetic microstructures that consider one prior β grain or multiple β grains (and thus prior β boundaries), simulations were conducted on both conditions of microstructures. </p> <p><br></p> <p>In the second portion of this thesis, simulations are conducted on two conditions of synthetic microstructures: models which contain 𝛼 lathes associated with one prior 𝛽 grain and models which contain multiple prior 𝛽 boundaries and the respective 𝛼 lathes. The goals of the simulations included: (1) lifing the different synthetic microstructures using a fatigue lifing model by way of the accumulated plastic strain energy density (APSED), (2) analyzing the microscopic localization of APSED at the prior β boundaries, and (3) analyzing the effects of the α lathes on the microscopic localization. This investigation aimed to further shed light on the effects of the additive manufacturing process and the implications of the resulting microstructure on the fatigue properties of AM Ti-6Al-4V. Furthermore, physics-based prognosis strategies similar to what is employed here will enable the rapid qualification of materials/structures and the ability to tailor component design on fatigue performance. </p>

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<p dir="ltr">I conducted an in-depth analysis of the frequency and severity of external load accidents involving Chinook helicopters over a period of 30 years. The literature review encompassed General Aviation (GA) and ground-based safety organizations, while the data analysis predominantly relied on secondary data from the Army Combat Readiness Center (ACRC). In conducting this study, I aimed to identify key trends, causes, and effects of these accidents, particularly emphasizing material failures, human errors, and the substantial impact of rotor downwash as horizontal wind velocities in proximity to the ground. The study's goal was to improve safety and operational efficiency in Chinook external load operations by identifying frequency and severity of accidents over a 30-year period. The hope was that this would provide valuable insights for improvements in risk mitigation techniques.</p><p dir="ltr">By using an exploratory secondary data analysis of both publicly available U.S. Army accidents and accident data provided by the U.S. ACRC, I found that Chinook rotor downwash, which manifests as horizontal wind velocity when in close proximity to the ground, is the most significant and underreported factor. Based on the findings of this research, I recommend improved classification and documentation of such accidents. The findings highlighted the urgency of updating training and operational procedures to effectively address the unique challenges posed by rotor downwash and high gross weights in proximity to the ground, typical of Chinook external load Pickup and Landing Zone (PZ/LZ) operations. Implementing these recommendations is expected to enhance safety measures in both training and practical operations, ultimately reducing future accidents and improving safety standards in the aviation industry.</p>

<p dir="ltr">This work focuses on the fracture behavior and failure mechanisms of Prepreg Platelet Molded Composites (PPMCs), which are characterized by meso-structural variability. The study investigates the interlaminar fracture toughness of PPMCs using both experimental and computational approaches, with a particular focus on Mode-I fracture testing. Cohesive zone models are developed to simulate interfacial behavior in composite laminates. The research introduces the concept of the platelet critical length problem and explores how platelet geometry, arrangement, and meso-structural features affect fracture toughness and energy absorption. Findings indicate that smaller platelets enhance fracture toughness through mechanisms like platelet bridging and crack deflection, while larger platelets provide more consistent fracture properties but exhibit greater variability in stiffness. This work offers valuable insights for optimizing PPMC performance in high-performance applications.</p>

<p>This work investigated the effects of varying the crystal sizes of ammonium perchlorate (AP) when embedded with a polymeric binder, hydroxyl-terminated polybutadiene (HTPB) on impact-induced temperature behavior.  AP and HTPB are the most used oxidizers and fuel binders in the aerospace solid rocket design industry. In this study, samples of 200 µm and 400µm coarse AP crystals in HTPB were constructed using a conventional hand-mixing method. Using a parametric optimization technique such as the Taguchi method, direct-ink-writing as the additive manufacturing process was used for achieving the required shape fidelity in printing HTPB and by introducing ultraviolet polymers to decrease the curing time.</p> <p>A drop hammer experiment in conjunction with an infrared camera was used to study the impact-induced behavior in the conventionally made AP-HTPB samples. The thermal images obtained from the camera at millisecond resolution are invaluable and provide information about distribution across the sample surface, and the evolution of temperature rise observed in the samples which are complex and not easily understood otherwise and therefore help in improving and attaining desired propellant performance. A two-sample t-Test has been utilized to infer the results and statistical nonsignificance has been observed in the highest temperature rises among 200 µm and 400 µm AP-HTPB sample conditions but a difference in temperature distribution has been observed. A much uniform distribution of temperature over the sample surface on impact is observed in thermal images of 200 µm AP-HTPB sample condition compared to 400 µm AP-HTPB sample condition.</p>

<div>Defects are unavoidable, life-limiting and dominant sites of damage and subsequent failure in a material. Ni-based superalloys are commonly used in high temperature applications and inevitably found to have defects in the form of inclusions, voids and microscopic cracks which are below the resolution of standard inspection techniques. A mechanistic understanding of the role of defects in such industrially relevant bulk polycrystalline material is essential for philosophies of design and durability to follow and ensure structural integrity of components in the inevitable presence of such defects. The current understanding of defect-mediated damage, in bulk Ni superalloys, is limited by experimental techniques that can capture the local micromechanical state of the material surrounding the defect. In this work, we combine mechanical testing with in-situ, non-destructive 3-D X-ray characterization techniques to obtain rich multi-modal datasets at the microscale to interrogate complex defect-microstructure interactions and elucidate the mechanisms of failure around defects. The attenuated X-ray beam, after passage through the material, is utilized through computed micro-tomography to characterize the defects owing to its sensitivity to density differences in the material. The diffracted X-ray beam, after illuminating the material, is employed through high energy diffraction microscopy in various modes to interrogate the evolving micromechanical state around the discovered defects.</div><div>Three case studies are performed with specimens made of a Ni-based superalloy specially designed and fabricated to have internal defects in the form of: (i) an inclusion, (ii) a microscopic crack, and (iii) voids. In each case, the grain scale information is investigated to reveal heterogeneity in the local micromechanical state of the material as a precursor for the onset of failure. Models and simulations based on finite element or crystal plasticity are utilized, wherever necessary, to assess the factors essential to the underlying mechanism of failure. In the first case study, the detrimental effects of an inclusion in initiating a crack upon cyclic loading is interrogated and the state of bonding, residual stresses, and geometrical stress concentrations around the inclusion are demonstrated to be of utmost importance. In the second case study, the propagation of a short fatigue crack through the microstructure is examined to reveal the crystallographic nature of crack growth through the (i) alignment of the crack plane with the most active slip system, (ii) the correlation between the crack growth rate and the maximum resolved shear stresses, and (iii) the dependence of the crack growth direction on microplasticity within grains ahead of the crack front. In the third case study, the role of voids in ductile failure under tensile loading is explored to illuminate the activation and operation of distinct mechanisms of inter-void shear and necking under the control of the local state of stress triaxiality and the local plasticity within the grains at critical sites of fracture.</div><div>In summary, a grain scale description of the micromechanical state has been unambiguously determined through experiments to examine the heterogeneity around defects in the material. It has enabled us to identify and isolate the nature of factors essential to the activation of specific mechanisms at the onset failure. The grain scale thus provides an ideal physical basis to understand the fundamentals of defect mediated damage and failure instilling trust in the predictive capabilities of models that incorporate the response of the grain structure. The generated datasets can be used to instantiate and calibrate such models at the grain level for higher fidelity. </div>

Computational modeling is essential for material and structural analyses for a multitude of reasons, including for the improvement of design and reducing manufacturing costs. However, the cost of commercial finite element packages prevent companies with limited financial resources from accessing them. Free finite element solvers, such as Warp3D, exist as robust alternatives to commercial finite element analysis (FEA) packages. This and other open-source finite element solvers are not necessarily easy to use. This is mainly due to a lack of a preprocessing framework, where users can generate meshes, apply boundary conditions and forces, or define materials. We developed a preprocessor for Warp3d, which is referred to as <i>W3DInput</i>, to generate input files for the processor. <i>W3DInput</i> creates a general framework, at no cost, to go from CAD models to structural analysis. With this preprocessor, the user can import a mesh from a mesh generator software – for this project, Gmsh was utilized – and the preprocessor will step the user through the necessary inputs for a Warp3D file. By using this preprocessor, the input file is guaranteed to be in the correct order and format that is readable by the solver, and makes it more accessible for users of all levels. With this preprocessor, five use cases were created: a cantilever beam, a displacement control test, a displacement control test with a material defined by a user-defined stress-strain curve, a crystal plasticity model, and pallet. Results were outputted to Exodus II files for viewing in Paraview, and the results were verified by checking the stress-strain curves. Results from these use cases show that the input files generated from the preprocessor functions were correct.

Among the many active materials in use today, piezoelectric composite patches have enabled notable advances in emerging technologies such as disturbance sensing, control of flexible structures, and energy harvesting. The macro fiber composite (MFC), in particular, is well known for its outstanding performance. Multiscale models are typically required for smart-structure design with MFCs. This is due to the need for predicting the macroscopic response (such as tip deflection under a transverse load or applied voltage) while accounting for the fact that the MFC has microscale details. Current multiscale models of the MFC exclusively focus on predicting the macroscopic response with homogenized material properties. There are a limited number of homogenized properties available from physical experiments and various aspects of existing homogenization techniques for the MFC are shown here to be inadequate. Thus, new homogenized models of the MFC are proposed to improve smart-structure predictions and therefore improve device design. It is notable that current multiscale modeling efforts for MFCs are incomplete since, after homogenization, the local fields such as stresses and electric fields have not been recovered. Existing methods for obtaining local fields are not applicable since the electrodes of the MFC are embedded among passive layers. Therefore, another objective of this work was to find the local fields of the MFC without having the computational burden of fully modeling the microscopic features of the MFC over a macroscale area. This should enable smart-structure designs with improved reliability because failure studies of MFCs will be enabled. Large-scale 3D finite element (FE) models that included microscale features were constructed throughout this work to verify the multiscale methodologies. Note that after creating a free account on cdmhub.org, many files used to create the results in this work can be downloaded from https://cdmhub.org/projects/ernestocamarena.<br><br>First, the Mechanics of Structure Genome (MSG) was extended to provide a rigorous analytical homogenization method. The MFC was idealized to consist of a stack of homogeneous layers where some of the layers were homogenized with existing rules of mixtures. For the analytical model, the electrical behavior caused by the interdigitated electrodes (IDEs) was approximated with uniform poling and uniform electrodes. All other assumptions on the field variables were avoided; thus an exact solution for a stack of homogeneous layers was found with MSG. In doing so, it was proved that in any such multi-layered composite, the in-plane strains and the transverse stresses are equal in each layer and the in-plane electric fields and transverse electric displacement are constant between the electrodes. Using this knowledge, a hybrid rule of mixtures was developed to homogenize the entire MFC layup so as to obtain the complete set of effective device properties. Since various assumptions were avoided and since the property set is now complete, it is expected that greater energy equivalence between reality and the homogenized model has been made possible. The derivation clarified what the electrical behavior of a homogenized solid with internal electrodes should be—an issue that has not been well understood. The behavior was verified by large-scale FE models of an isolated MFC patch.<br> <br>Increased geometrical fidelity for homogenization was achieved with an FE-based RVE analysis that accounted for finite-thickness effects. The presented theory also rectifies numerous issues in the literature with the use of the periodic boundary conditions. The procedure was first developed without regard to the internal electrodes (ie a homogenization of the active layer). At this level, the boundary conditions were shown to satisfy a piezoelectric macrohomogeneity condition. The methodology was then applied to the full MFC layup, and modifications were implemented so that both types of MFC electrodes would be accounted for. The IDE case considered nonuniform poling and electric fields, but fully poled material was assumed. The inherent challenges associated with these nonuniformities are explored, and a solution is proposed. Based on the homogenization boundary conditions, a dehomogenization procedure was proposed that enables the recovery of local fields. The RVE analysis results for the effective properties revealed that the homogenization procedure yields an unsymmetric constitutive relation; which suggests that the MFC cannot be homogenized as rigorously as expected. Nonetheless, the obtained properties were verified to yield favorable results when compared to a large-scale 3D FE model.<br> <br>As a final test of the obtained effective properties, large-scale 3D FE models of MFCs acting in a static unimorph configuration were considered. The most critical case to test was the smallest MFC available. Since none of the homogenized models account for the passive MFC regions that surround the piezoelectric fiber array, some of the test models were constructed with and without the passive regions. Studying the deflection of the host substrate revealed that ignoring the passive area in smaller MFCs can overpredict the response by up to 20%. Satisfactory agreement between the homogenized models and a direct numerical simulation were obtained with a larger MFC (about a 5% difference for the tip deflection). Furthermore, the uniform polarization assumption (in the analytical model) for the IDE case was found to be inadequate. Lastly, the recovery of the local fields was found to need improvement.<br><br><br>

First, the theory of MSG is extended to aperiodic heterogeneous solid structures. Integral constraints are introduced to decompose the displacements and strains of the heterogeneous material into a fluctuating part and a macroscopic part, of which the macroscopic part represents the responses of the homogenized material. One advantage of this theory is that boundary conditions are not required. Consequently, it is capable of handling micro-structures of arbitrary shapes. In addition, periodic constraints can be incorporated into this theory as needed to model periodic or partially periodic materials such as textile composites. In this study, the newly developed method is employed to investigate the finite thickness effect of textile composites.<div><br></div><div>Second, MSG is enabled to deal with Timoshenko beam-like structures with spanwise heterogeneity, which provide higher accuracy than the previous available Euler–Bernoulli beam model. Its reduced form, the MSG beam cross sectional analysis, is found to be able to analyze generalized free-edge problems with arbitrary layups and subjected to general loads. In this method, the only assumption applied is that the laminate is long enough so that the Saint-Venant principle can be adopted. There is no limitation on the cross section of the laminate since no ad hoc assumption is involved with the microstructure geometry. This method solve the free-edge problem from a multiscale simulation point of view.<br></div><div><br></div>

<p>Modern structural materials utilize tailored microstructures to retain peak performance within the most volatile operating conditions. Features such as grain size, grain boundary (GB) character and morphology and secondary phases are just a few of the tunable parameters. By tailoring these types of microstructural features, the deformation behavior of the material is also altered. The localization of plastic strain directly correlated to material failure. Thus, a systematic approach was utilized to understand the effect of microstructural features on the localization of plastic deformation utilizing digital image correlation (DIC). First, at the macroscopic scale, strain accumulation is known to form parallel to the plane of maximum shear stress. The local deviations in the deformation pathways at the meso-scale are investigated relative to the plane of maximum shear stress. The deviations in the deformation pathways are observed to be a function of the accumulated local plastic strain magnitude and the grain size. Next, strains characterized via DIC were used to calculate a value of incremental slip on the active slip systems and identify cases of slip transmission. The incremental slip was calculated based on a Taylor-Bishop-Hill algorithm, which determined a qualitative assessment of deformation on a given slip system, by satisfying compatibility and identifying the stress state by the principle of virtual work. Inter-connected slip bands, between neighboring grains, were shown to accumulate more incremental slip (and associated strain) relative to slip bands confined to a single grain, where slip transmission did not occur. These results rationalize the role of grain clusters which lead to intense strain accumulation and thus serve as potential sites for fatigue crack initiation. Lastly, at GB interfaces, the effect of GB morphology (planar or serrated) on the cavitation behavior was studied during elevated temperature dwell-fatigue at 700 °C. The resulting γ′ precipitate structures were characterized near GBs and within grains. Along serrated GBs coarsened and elongated <a>γ′ </a>precipitates formed and consequently created adjacent regions that were denuded of γ′ precipitates. Dwell-fatigue experiments were performed at low and high stress amplitudes which varied the amount of imparted strain on the specimens.<a> Additionally, the regions denuded of the γ′ precipitates were observed to localize strain and to be initial sites of cavitation.</a> <a>These results present a quantitative strain analysis between two GB morphologies, which provided the micromechanical rationale for the increased proclivity for serrated GBs to form cavities.</a></p>