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Automobile manufacturers are interested in lightweight materials, including magnesium, to increase vehicle fuel economy, improve performance and reduce emissions. In this work the deformation behavior of as-cast and rolled magnesium AZ31 alloy has been studied. In as-cast material, it was found that reheating at 400°C and above for 60 minutes increased the homogeneity of the as-cast structure and gave rise to repeatable deformation. At compression temperatures above 300°C dynamic recrystallization occurred; below 200°C, there was significant twinning. Annealing completely recrystallized the structure deformed below 200°C, but did not change the dynamically recrystallized structure. AZ31 alloy was also rolled at temperatures of 350, 400 and 450°C and rolling speeds of 20 and 50 rpm for 15 and 30% reduction in thickness to produce sheet. Before rolling, the alloy was preheated for I and 10 hours at the rolling temperatures. The sheets were then tensile tested at 300, 400 and 450°C with strain rates of 0.1, 0.01 and 0.001s-1. The flow curves and microstructures indicated that the tensile deformation mechanism changed with processing conditions. Two deformation mechanisms were present in the magnesium sheet depending on the strain rate and grain size. At slow strain rates and small grain size, the active deformation mechanism was grain boundary sliding. As grain sizes increased there was also a component of dislocation creep. At the fast strain rate, the deformation mechanism, regardless of grain size, was dislocation creep. At a true strain rate of 0.001s-1, it was found that rolling at 350°C with 30% reduction per pass yielded the finest microstructure and subsequently, the best hot deformation characteristics. At a true strain rate of 0.1s-1, rolling at 450°C with 30% reduction per pass yielded a coarser, more recrystallized microstructure with best hot deformation characteristics.

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Magnesium alloys have a great potential in automotive industries, compared to steel and aluminium (Al), Magnesium (Mg) is much lighter and this weight reduction improves fuel efficiency and lowers green gas emission. Due to its hexagonal crystal structure, magnesium has poor ductility at room temperature. Magnesium's ductility improves significantly above about 200°C due to thermal activation of additional slip systems. This has lead to efforts to form auto-body panels with commercial AZ31 magnesium sheet at elevated temperatures. In this work, various AZ31 magnesium alloy materials were used to investigate the influence of deformation conditions on texture and microstructure. Moreover, it is to define the correlation between formability and different deformation mechanisms. / It was observed that only basal slip and twinning contributed to room temperature deformation. As deformation temperature increased, an increase in ductility in Mg contributed to dynamic recrystallization occurring readily at elevated temperatures (≥300°C). Even coarse grain material experienced significant tensile elongation due grain refinement. Depending on temperature and strain rate, different deformation mechanisms were activated and lead to different failure modes (moderate necking, cavity, strong necking). More specifically, deformation at elevated temperature in the low-strain-rate regime with stress exponent n about 2-3 and activation energy close to grain-boundary diffusion of Mg (Q = 92 kJ/mol) is characteristic of GBS. Deformation at elevated temperature in the high strain rate regime showed that the stress exponent increased to a value close to 5 and that the activation energy was consistent with the one for Mg self-diffusion (135 kJ/mol) and for diffusion of Al in Mg (143 kJ/mol). This was indicative of a dislocation creep deformation mechanism. Plus the six-fold symmetric patterns of the {1 100} and {1120} pole figures and the splitting of basal plane distribution are another indication of slip mechanism or of dislocation creep mechanism. / The optimum deformation behavior for AZ31 sheet was found to be for the material with fine grain microstructure. The highest elongation of 265% was obtained with the material having initial grain size of 8 mum. In addition, strain-rate sensitivity, which is a good indication of material's ductility, also was the highest in material with 8 mum grain size. As a common trend, the strain-rate sensitivity increased with decreasing strain rate, increasing temperature and decreasing grain size. / In terms of drawability of AZ31 sheet, the deformation controlled by GBS resulted in a fair drawability/formability property with r-value about 1 whereas a deformation mechanism controlled by dislocation creep showed a good drawability with r-value above 1.5. Due to activation of additional slip systems (non-basal <a> and <c+a>), the thinning of the sheet was prevented, in particular at deformation conditions of 450°C with 0.1s-1 where r-value was highest. This deformation condition might suggest good forming process parameters, especially for deep drawing, for the commercial AZ31 sheet under investigation. A preliminary study of Forming Limit Diagram for AZ31 sheet was performed by the Limit Dome Height test method at 300°C. The FLD0 of AZ31 was found to be 67%; the part depth of biaxial forming was 1.86 in; and the maximum LDH varied from 2.4 to 2.6 in.

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Actuator applications of shape memory alloys have typically been limited by their phase transformation temperatures to around 100 degrees C. However, recently with a focus on aerospace and turbomachinery applications there have been successful efforts to increase the phase transformation temperatures. Several of these alloy development efforts have involved ternary and quaternary elemental additions (e.g., Pt, Pd, etc.) to binary NiTi alloys. Experimentally assessing the effects of varying composition and thermo-mechanical processing parameters can be cost intensive, especially when expensive, high-purity elemental additions are involved. Thus, in order to save on development costs there is value in establishing a methodology that facilitates the fabrication, processing and testing of smaller specimens, rather than larger specimens from commercial billets. With the objective of establishing such a methodology, this work compares thermo-mechanical test results from bulk dog-bone tensile Ni29.5Ti50.5Pd20 samples (7.62 mm diameter) with that of thin wires (100 μm-150 µm diameter) extracted from comparable, untested bulk samples by wire electrical-discharge machining (EDM). The wires were subsequently electropolished to different cross-sections, characterized with Scanning Electron Microscopy, Transmission Electron Microscopy and Energy Dispersive X-Ray Spectroscopy to verify the removal of the heat affected zone following EDM and subjected to Laser Scanning Confocal Microscopy to accurately determine their cross-sections before thermo-mechanical testing. Stress-strain and load-bias experiments were then performed on these wires using a dynamic mechanical analyzer and compared with results established in iv previous studies for comparable bulk tensile specimens. On comparing the results from a bulk tensile sample with that of the micron-scale wires, the overall thermomechanical trends were accurately captured by the micron-scale wires for both the constrained recovery and monotonic tensile tests. Specifically, there was good agreement between the stress-strain response in both the martensitic and austenitic phases, the transformation strains at lower stresses in constrained recovery, and the transformation temperatures at higher stresses in constrained recovery. This work thus validated that carefully prepared micron-diameter samples can be used to obtain representative bulk thermo-mechanical properties, and is useful for fabricating and optimizing composition and thermomechanical processing parameters in prototype button melts prior to commercial production. This work additionally assesses potential applications of high temperature shape memory alloy actuator seals in turbomachinery. A concept for a shape memory alloy turbine labyrinth seal is also presented. Funding support from NASA’s Fundamental Aeronautics Program, Supersonics Project (NNX08AB51A) and Siemens Energy is acknowledged.

To date the commercial use of shape memory alloys (SMAs) has been mostly limited to binary NiTi alloys with transformation temperatures approximately in the -100 to 100 ºC range. In an ongoing effort to develop high-temperature shape memory alloys (HTSMAs), ternary and quaternary additions are being made to binary NiTi to form NiTi-X (e.g., X: Pd, Pt, Au and Hf) alloys. Stability and repeatability can be further increased at these higher temperatures by limiting the stress, but the tradeoff is reduced work output and stroke. However, HTSMAs operating at decreased stresses can still be used effectively in actuator applications that require large strokes when used in the form of springs. The overall objective of this work is to facilitate the development of HTSMAs for use as high-force actuators in active/adaptive aerospace structures. A modular test setup was assembled with the objective of acquiring stroke, stress, temperature and moment data in real time during joule heating and forced convective cooling of Ni19.5Ti50.5Pd25Pt5 HTSMA springs. The spring actuators were evaluated under both monotonic axial loading and thermomechanical cycling. The role of rotational constraints (i.e., by restricting rotation or allowing for free rotation at the ends of the springs) on stroke performance was also assessed. Recognizing that evolution in the material microstructure results in changes in geometry and vice versa in HTSMA springs, the objective of the present study also included assessing the contributions from the material microstructural evolution, by eliminating contributions from changes in geometry, to overall HTSMA spring performance. The finite element method (FEM) was used to support the analytical analyses and provided further insight into the behavior and heterogeneous stress states that exist in these spring actuators. iv Furthermore, with the goal of improving dimensional stability there is a need to better understand the microstructural evolution in HTSMAs that contributes to irrecoverable strains. Towards this goal, available Ni29.5Ti50.5Pd20 neutron diffraction data (from a comparable HTMSA alloy without the solid solution strengthening offered by the Pt addition) were analyzed. The data was obtained from in situ neutron diffraction experiments performed on Ni29.5Ti50.5Pd20 during compressive loading while heating/cooling, using the Spectrometer for Materials Research at Temperature and Stress (SMARTS) at Los Alamos National Laboratory. Specifically, in this work emphasis was placed on neutron diffraction data analysis via Rietveld refinement and capturing the texture evolution through inverse pole figures. Such analyses provided quantitative information on the evolution of lattice strain, phase volume fraction (including retained martensite that exists above the austenite finish temperature) and texture (martensite variant reorientation and detwinning) under temperature and stress. Financial support for this work from NASA’s Fundamental Aeronautics Program Supersonics Project (NNX08AB51A), Subsonic Fixed Wing Program (NNX11AI57A) and the Florida Center for Advanced Aero-Propulsion (FCAAP) is gratefully acknowledged. It benefited additionally from the use of the Lujan Neutron Scattering Center at Los Alamos National Laboratory, which is funded by the Office of Basic Energy Sciences (Department of Energy) and is operated by Los Alamos National Security LLC under DOE Contract DE-AC52-06NA25396.

Shape memory alloy (SMA) materials such as nitinol have unique properties associated with the shape recovery effect and the material’s phase changes that have been used in a variety of actuator and sensing applications. By embedding SMA elements into host composite materials, control or modification of the SMA hybrid composite’s structural properties can be accomplished in-service, thereby increasing the hybrid composite’s structural functionality. Previous studies addressed increasing composite materials’ functionality by enabling in-service control of their dynamic response. Utilizing the SMA’s substantial recovery stress and capacity to dissipate strain energy to increase the hybrid composite’s static functionality is addressed herein. Specific applications for SMA hybrid composites include improving composite material’s impact damage resistance and composite cylinder stress and deflection control. In stress and deflection control of cylindrical structures, SMA actuators are placed within the composite cylinder to form an active compound cylinder. The active SMA elements can significantly reduce the internal pressure-induced radial dilation and creep so that under severe loading, piston to cylinder tolerances may be maintained. Similar to a conventional metallic compound cylinder, the active compound cylinder also reduces peak cylinder hoop stresses. Hybridizing composites with nitinol improves their impact resistance because of nitinol’s tremendous capacity to absorb impact strain energy through the stress-induced martensitic phase transformation. The amount of impact damage is reduced and the material’s resistance to impact perforation at various velocities is improved. The experimental response of nitinol hybrid composites and the associated mechanics are presented. The unique toughness and resistance to permanent deformation that is a result of the stress-induced martensitic phase transformation enables the nitinol to absorb on the order of 4 times the strain energy of high alloy steel and 16 times that of many graphite/epoxy composites. In most static applications where SMA elements are used for reinforcement, maintaining the integrity of the interface between the SMA elements and the host polymeric matrix composite material is critical to operation. The relationship between preparation of SMA elements for hybrid composite fabrication and interfacial bond strength is presented to address this issue. The mechanics of interfacial shear failure between SMA element and composite is also presented. / Ph. D.

Microstructural features at different scales affect the constitutive stress-strain response and the fatigue crack initiation life in Ni-base superalloys. While numerous efforts have been made in the past to experimentally characterize the effects of these features on the stress-strain response and/or the crack initiation life, there is a significant variability in the data with sometimes contradictory conclusions, in addition to the substantial costs involved in experimental testing. Computational techniques can be useful tools to better understand these effects since they are relatively inexpensive and are not restricted by the limitations in processing techniques. The effect of microstructure on the stress-strain response and the variability in fatigue life were analyzed using two Ni-base superalloys; DS GTD111 which is a directionally solidified Ni-base superalloy, and IN100 which is a polycrystalline Ni-base superalloy. Physically-based constitutive models were formulated and implemented as user material subroutines in ABAQUS using the single crystal plasticity framework which can predict the material stress-strain response with the microstructure-dependence embedded into them. The model parameters were calibrated using experimental cyclic stress-strain histories. A computational exercise was employed to quantify the influence of idealized microstructural variables on the fatigue crack initiation life. Understanding was sought regarding the most significant microstructure features using explicit modeling of the microstructure with the aim to predict the variability in fatigue crack initiation life and to guide material design for fatigue resistant microstructures. Lastly, it is noted that crystal plasticity models are often too computationally intensive if the objective is to model the macroscopic behavior of a textured or randomly oriented 3-D polycrystal in an engineering component. Homogenized constitutive models were formulated and implemented as user material subroutines in ABAQUS, which can capture the macroscale stress-strain response in both DS GTD111 and IN100. Even though the study was conducted on two specific Ni-base superalloys; DS GTD111 and IN100, the objective was to develop generic frameworks which should also be applicable to other alloy systems.