Cuttlebone, the endoskeleton of cuttlefish, offers an intriguing biological structural model for designing low-density cellular ceramics with high stiffness and damage tolerance. Cuttlebone is highly porous (porosity ~93%) and lightweight (density less than 20% of seawater), constructed mainly by brittle aragonite (95 wt%), but capable of sustaining hydrostatic water pressures over 20 atmospheres and exhibits energy dissipation capability under compression comparable to many metallic foams (~4.4 kJ/kg). Here we computationally investigate how such a remarkable mechanical efficiency is enabled by the multiscale structure of cuttlebone. Using the common cuttlefish, Sepia Officinalis, as a model system, we first conducted high-resolution synchrotron micro-computed tomography (µ-CT) and quantified the cuttlebone's multiscale geometry, including the 3D asymmetric shape of individual walls, the wall assembly patterns, and the long-range structural gradient of walls across the entire cuttlebone (ca. 40 chambers). The acquired 3D structural information enables systematic finite-element simulations, which further reveal the multiscale mechanical design of cuttlebone: at the wall level, wall asymmetry provides optimized energy dissipation while maintaining high structural stiffness; at the chamber level, variation of walls (number, pattern, and waviness amplitude) contributes to progressive damage; at the entire skeletal level, the gradient of chamber heights tailors the local mechanical anisotropy of the cuttlebone for reduced stress concentration. Our results provide integrated insights into understanding the cuttlebone's multiscale mechanical design and provide useful knowledge for the designs of lightweight cellular ceramics. Upon the prior curvature analysis of the cuttlebone walls, we discovered that the walls were primarily "saddle-shaped". Thus, the characterization of different curvatures, varying between flat, domed, saddled, or cylindrical surfaces, were explored. A mathematical model was utilized to generate multiple walls with different curvature characteristics. We observed the mechanical performance of these walls via finite-element analysis and formulated different techniques for designing effective ceramic structures through incorporation of curvature. / Master of Science / The cuttlefish is a marine species that instead of having an inflatable swim bladder like fish, is a mollusk capable of swimming by utilizing their skeleton, called the cuttlebone. The cuttlefish can freely traverse the waters by controlling the flow of water in and out of their brittle skeletons, changing their buoyancy. For this reason, the cuttlebone must be very porous yet strong to withstand the deep-water pressures, enticing an interest for closer observation of the structure which may be useful in engineering applications involving ceramic structures. In this study, we examined an actual cuttlebone structure to better visualize its features with high-resolution synchrotron micro-computed tomography (µ-CT) and tabulated its mechanical performance through a variety of tests using computational software. The skeletal design of the cuttlebone consists of multiple layered chambers supported by wavy, pillar-like walls. It was revealed that the cuttlebone is remarkable due to its multiscale design: the asymmetric geometry of the walls are designed to tolerate considerable amounts of energy while a stiff construction; at the chamber level, variation of walls (number, pattern, and waviness amplitude) helps avoid complete destruction of the structure in the event of an excessive force; at the entire skeletal level, various of chamber heights reduces inflicted stress in concentrated regions of the cuttlebone. The wavy walls were also observed to retain a saddle-shaped curviness, versus simple flat, domed, or cylindrical shaped walls. This created an incentive to explore the effects of curvature on the structural integrity of brittle ceramic structures. We developed an effective way for generating walls with different curvatures and observed the mechanical performance of each wall by crushing them in computer simulations. It was identified that adding curvature to brittle walls prolonged the failure period significantly. While the cylindrical walls were found to be rather stiff, saddle-shaped walls, although not capable of withstanding as much force as flat or cylindrical walls, has a more progressive failure behavior meanwhile maintaining high energy absorption, hence the saddled walls of the cuttlebone to allow maintenance and self-repair in damaged regions.

Orientador: Maria Helena Robert / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-11-08T18:37:47Z (GMT). No. of bitstreams: 1 Delbin_Daniel_M.pdf: 8551361 bytes, checksum: 770e9d00eeb959cc6e40cf3f314faa4e (MD5) Previous issue date: 2006 / Resumo: Neste trabalho é estudada a viabilidade de produção de esponjas metálicas pela conformação de pasta tixotrópica da liga A2011, sobre camada de agente bloqueador (NaCl) posteriormente removido para formação da porosidade. Investiga-se a influência da temperatura de tratamento térmico, para obtenção da pasta semi-sólida, e da granulometria do agente bloqueador, na estrutura formada do material celular (aspecto geral, caracterização qualitativa e quantitativa dos poros, microestrutura da parede celular e densidade) e nas características de processo (forças de tixoforjamento e capacidade de penetração da pasta). São produzidos cilindros de material poroso metálico tipo sanduíche, compostos de camada porosa entre camadas maciças da liga, com três diferentes classes de porosidade: fina, média e grosseira. As esponjas foram submetidas à tomografia computadorizada e à análise metalográfica para sua caracterização estrutural. Os resultados obtidos mostram a viabilidade de obtenção de esponjas metálicas utilizando a tecnologia de semi-sólidos e o tipo de bloqueador utilizado. O sucesso do processo depende da fração líquida presente na pasta metálica tixotrópica, reduzida fração líquida pode resultar em incompleta infiltração e compressão das partículas do agente bloqueador. Nas condições analisadas a granulometria do agente bloqueador não teve influência sensível na qualidade do produto. A densidade do material poroso aumenta com o aumento da temperatura de processo, devido ao aumento da espessura de paredes metálicas na estrutura porosa / Abstract: The work analyses the possibility of the production of cellular material by pressing the A2011 alloy in the thixotropic semi-solid state, into a space holder pre-form. Space holder particles used are NaCl, which are removed from the product after the forming operation, resulting the porous material. It is investigated the influence of the thixoforming temperature and the size of space holder particles, in the structure of the obtained porous material (general aspect, quantitative and qualitative characterization of porosity, microstructure of cell walls and density of the product), as well as in the processing characteristics (required forces for infiltration, penetration ability of the slurry in the salt pre-form). Cylindrical samples, sandwich type, with a porous layer inserted between layers of compact alloy are produced, presenting three different ranges of porosity. The cellular material obtained contains opened porosity, being characterized as sponge. Products were analyzed by tomography and metallographic techniques. Results show that the proposed process is able to produce acceptable porous material, with a simple and low cost technique. The quality of the product depends rather on the processing temperature than on the size of space holder particles. Low liquid fraction in the thixotropic slurry can lead to incomplete infiltration and deformation of the pre-form. In the analyzed conditions, influence of the size of space holder particles could be observed neither in the processing ability nor in the quality of the product. Density of produced porous material increases as processing temperature increases, due to the increase of thickness of cell walls / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

A paradigm shift is underway in which the classical materials selection approach in engineering design is being replaced by the design of material structure and processing paths on a hierarchy of length scales for specific multifunctional performance requirements. In this dissertation, the focus is on designing mesoscopic material and product topology?? geometric arrangement of solid phases and voids on length scales larger than microstructures but smaller than the characteristic dimensions of an overall product. Increasingly, manufacturing, rapid prototyping, and materials processing techniques facilitate tailoring topology with high levels of detail. Fully leveraging these capabilities requires not only computational models but also a systematic, efficient design method for exploring, refining, and evaluating product and material topology and other design parameters for targeted multifunctional performance that is robust with respect to potential manufacturing, design, and operating variations. In this dissertation, the Robust Topological Preliminary Design Exploration Method is presented for designing complex multi-scale products and materials by topologically and parametrically tailoring them for multifunctional performance that is superior to that of standard designs and less sensitive to variations. A comprehensive robust design method is established for topology design applications. It includes computational techniques, guidelines, and a multiobjective decision formulation for evaluating and minimizing the impact of topological and parametric variation on the performance of a preliminary topological design. A method is also established for multifunctional topology design, including thermal topology design techniques and multi-stage, distributed design methods for designing preliminary topologies with built-in flexibility for subsequent modification for enhanced performance in secondary functional domains. Key aspects of the approach are demonstrated by designing linear cellular alloys??ered metallic cellular materials with extended prismatic cells?? three applications. Heat exchangers are designed with increased heat dissipation and structural load bearing capabilities relative to conventional heat sinks for microprocessor applications. Cellular materials are designed with structural properties that are robust to dimensional and topological imperfections such as missing cell walls. Finally, combustor liners are designed to increase operating temperatures and efficiencies and reduce harmful emissions for next-generation turbine engines via active cooling and load bearing within topologically and parametrically customized cellular materials.

Ceramic cellular solids, mainly honeycombs and foams, are a novel class of composite materials where one phase is an interconnected network of solid struts or plates and the other one an empty phase or possibly a fluid. Honeycombs are an array of two dimensional prismatic cells whereas in foams the arrangements of cells are three dimensional polyhedral cells. Unlike solids, the properties of honeycombs are based on three major variables i.e. a) relative density (p* /p s where p* is the density of the cellular material and ps that of the solid of which it is made) b) cell wall material and c) geometry of the cells. Because of the flexibility in tailoring these variables, cellular solids can be engineered to exhibit a unique combination of mechanical and thermal properties for diversified thermostructural applications. Ceramic based honeycombs fabricated out of cordierite (2MgO.2Al2O35SiO2), mullite (3Al2O32SiO2), cordierite: mullite (2MgO.2Al2O35SiO2) with specific configurations are the leading candidates for many of the applications such as substrates for catalytic converters, molten metal filters, air heaters and heat exchangers etc. Zirconia by the virtue of its high fracture toughness and low thermal conductivity and high refractoriness is an interesting ceramic material and explored for versatile applications. However, no significant efforts have been reported to produce zirconia/alumina and their composite based honeycomb structures and also they have not been explored for their thermo-mechanical and energy absorption based applications. In the present study, looking at the possible potential applications of the honeycombs of Zirconia/alumina and their composites such as solid oxide fuel cells, high temperature filters, blast protection tiles etc., attempts are made to fabricate honeycomb structures. Chapter 1 of the thesis describes the detailed literature survey that has been carried out using advanced search packages regarding the evolution of ceramic honeycomb structures and their properties followed by the advantages of zirconia/alumina and their composites as candidate materials for targeted applications. Literature survey also covers the various processing techniques, characterization procedures with special emphasis on the thermo-mechanical properties. Chapter II describes attempts on developing an optimum scheme of processing of zirconia honeycomb which includes selection of precursor oxides, mixing of formulations, dough making based on viscosity measurements, shaping by extrusion, microwave drying, debinding and sintering to obtain the defect free monolithic structures keeping in view of the scale up possibilities. The chapter also describes a specially developed die fabrication process with innovative machining procedures. (Patent no. 198045). Sintered honeycombs were also characterized for their critical physiochemical properties. In chapter III mechanical characterization of honeycomb samples is reported after subjecting them to compression testing with varying cell channel orientation, compositions and configurations. It is observed that all honeycombs, irrespective of the composition and configuration exhibited anisotropic behavior. In addition, the anisotropy increases with the rib thickness and decreases with increase in the unit cell length. Thermal conductivity measurement studies of the honeycombs are reported in chapter IV. Two types of measurement techniques viz. laser diffraction and monotonic heating technique have confirmed the reduction of thermal conductivity of the honeycomb samples as compared to their solid counterpart. It is observed that the finer channel honeycombs offer low thermal conductivity as compared to the coarser channel when tested across the channel direction. For equivalent relative density, the thermal conductivity value for triangular channel is found to be more as compared to the square channel. Also, the thermal conductivity values were found less when measured across the channel as compared to the values when measured along the channels. The thermal conductivity value for fine channel zirconia-alumina composite honeycombs was found much less than the thermal conductivity of the alumina matrix. Chapter V summarises the implications of the study, conclusions and the target applications.

Ce travail porte sur l'incorporation de nanorenforts biosourcés, c'est-à-dire des nanofibrilles de cellulose (NFC), dans les matériaux composites à matrice polymère et les mousses. Ces nouveaux matériaux biosourcés peuvent par exemple être utilisés pour la conception de structures sandwich. L'étude à caractère expérimental, théorique et numérique s'articule autour de trois axes visant à optimiser tant les procédés d'élaboration que les propriétés en service de ces matériaux.Dans un premier temps, la rhéologie des suspensions concentrées de NFC, fluides à seuil thixotropes, a été étudiée aux échelles macro- et mésoscopiques en utilisant un dispositif original de rhéométrie couplé à des mesures de champs cinématiques par vélocimétrie ultra-sonore. Nous montrons ainsi que l'écoulement des suspensions de NFC est fortement hétéro-gène et présente des glissements aux parois, de multiples bandes de cisaillement couplés avec des écoulements de type « bouchon ». Sur la base de cette étude, un modèle rhéolo-gique multi-échelles est proposé. Ce modèle tient compte d'une part de l'architecture aniso-trope des réseaux connectés de NFC dans ces suspensions, et d'autre part des interactions mécaniques et physico-chimiques aux échelles nanométriques. Il permet de montrer que les interactions colloïdales et hydrodynamiques, ainsi que la tortuosité et l'orientation des NFC jouent un rôle majeur sur la contrainte seuil et sur le comportement rhéofluidifiant de ces suspensions.Dans un deuxième temps, des nanocomposites à matrice polymère ont été élaborés sous forme de films en faisant varier sur une très grande plage la fraction volumique de NFC. En utilisant d'une part des techniques de microscopie (AFM, MEB) et de diffraction aux rayons X, et d'autre part des essais mécaniques (traction, DMA) nous montrons (i) que les NFC ont une orientation plane et s'organisent en réseaux connectés par des liaisons hydro-gènes, (ii) que ces réseaux jouent un rôle majeur sur le comportement mécanique des nano-composites et (iii) que le comportement élastique des nanocomposites est bien en deçà des prévisions données par les modèles micromécaniques de la littérature. De là, nous proposons un modèle multi-échelles alternatif où les principaux nano-mécanismes de déformation sont ceux se produisant dans les parties amorphes des NFC et au niveau des très nombreuses interfaces entre NFC.Enfin, nous avons étudié l'influence des conditions d'élaboration, de la nature et de la con-centration des NFC sur les microstructures (microtomographie synchrotron à rayons X), les propriétés mécaniques (essais de compression) et les micro-mécanismes de déformation (essai in situ en microtomographie) de mousses préparées par cryodessiccation de suspensions aqueuses de NFC. / This study focuses on the use of cellulose nanofibrils (NFCs) as bio-based nano-reinforcement in polymer composites and foams. These renewable materials can be used in place of traditional materials such as for instance to produce sandwich panels. This experi-mental, theoretical and numerical work aims at optimizing the processing of these NFC-based materials as well as their use properties.In the first part of this work, the rheology of concentrated NFC suspensions, that behave as thixotropic yield stress fluids, is investigated at macro- and mesoscales using an original rheo-ultrasonic velocimetry (rheo-USV) setup allowing the local flow kinematic to be obtai-ned. We show that the flow of NFC suspensions is highly heterogeneous and exhibits com-plex situations with the coexistence of wall slippage, multiple shear bands and plug-like flow bands. Using this experimental database, we develop an original multiscale rheological model for the prediction of the rheology of NFC suspensions. The model takes into account the anisotropic fibrous nature of NFC networks as well as colloidal and mechanical interaction forces occurring at the nanoscale. The model predictions prove that colloidal and hydrody-namic interaction forces together with the orientation and the wavy nature of NFCs play a major role on the yield stress and shear thinning behaviour of the suspensions.In the second part of this work, NFC-reinforced polymer nanocomposite films are processed for a wide range of NFC contents. Using advanced microscopy techniques (AFM, SEM), X-ray diffraction and mechanical tests (tensile and DMA tests), we show (i) that NFCs form highly connected nanofibrous structures with in-plane random orientation, (ii) that these connected NFC networks play a leading role on the mechanical behaviour of the nanocompo-sites and (iii) that the elastic properties of nanocomposite films are much lower than those predicted from the micromechanical models of the literature. In light of these observations, we propose an alternative multiscale model in which the main involved deformation nano-mechanisms are those occurring both in the amorphous segments of the nanofibers and in the numerous nanofiber-nanofiber contact zones.Finally, in a third part we focus on the influence of the processing conditions, the suspension type and the NFC concentration on the microstructure (using X-ray synchrotron microto-mography), the mechanical properties (using compression tests) and the deformation micro-mechanisms (using in situ compression test with X-ray microtomography) of various foams prepared from NFC suspensions by freeze-drying.

Selective laser melting (SLM) is an additive manufacturing process which enables the creation of intricate components from high performance alloys. This facilitates the design and fabrication of new cellular materials for blast and impact mitigation, where the performance is heavily influenced by geometric and material sensitivities. Design of such materials requires an understanding of the relationship between the additive manufacturing process and material properties at different length scales: from the microstructure, to geometric feature rendition, to overall dynamic performance. To date, there remain significant uncertainties about both the potential benefits and pitfalls of using additive manufacturing processes to design and optimise cellular materials for dynamic energy absorbing applications. This investigation focuses on the out-of-plane compression of stainless steel cellular materials fabricated using SLM, and makes two specific contributions. First, it demonstrates how the SLM process itself influences the characteristics of these cellular materials across a range of length scales, and in turn, how this influences the dynamic deformation. Secondly, it demonstrates how an additive manufacturing route can be used to add geometric complexity to the cell architecture, creating a versatile basis for geometry optimisation. Two design spaces are explored in this work: a conventional square honeycomb hybridised with lattice walls, and an auxetic stacked-origami geometry, manufactured and tested experimentally here for the first time. It is shown that the hybrid lattice-honeycomb geometry outperformed the benchmark metallic square honeycomb in terms of energy absorption efficiency in the intermediate impact velocity regime (approximately 100 m/s). In this regime, the collapse is dominated by dynamic buckling effects, but wave propagation effects have yet to become pronounced. By tailoring the fold angles of the stacked origami material, numerical simulations illustrated how it can be optimised for specific impact velocity regimes between 10-150 m/s. Practical design tools were then developed based on these results.

Made available in DSpace on 2016-12-08T17:19:19Z (GMT). No. of bitstreams: 1 Danilo Guth.pdf: 5524444 bytes, checksum: 0d000481efd76a74f714599b9ac7f404 (MD5) Previous issue date: 2012-08-24 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Inspirados por materiais encontrados na natureza, pesquisadores têm estudado a utilização de materiais celulares em diversas aplicações como biomedicina, engenharia aeroespacial e militar. O ganho em relação ao material base é a excelente relação entre peso e propriedades diversas como: rigidez ao cisalhamento; condutividade térmica/elétrica; absorção de impacto, ruído e vibrações. Uma classe específica são os materiais constituídos por células treliçadas. Estes possuem estrutura periódica, formada por células-base constituídas de barras distribuídas espacialmente no domínio da célula. Modernos processos de fabricação vêm viabilizando a confecção das células em escalas micro e nanométricas. Técnicas para obtenção de novas configurações são objeto de diversos estudos que buscam obter estruturas ótimas para uma dada função multiobjetivo. O presente trabalho implementa o uso de programação quadrática sequencial para a obtenção de células-base otimizadas para funções termomecânicas incluindo a maximização do módulo de cisalhamento, módulo volumétrico, coeficiente de Poisson e condutividade térmica, permitindo a inclusão de restrições de isotropia. A determinação das propriedades macroscópicas é obtida através do método da homogeneização. Diversos resultados são obtidos para os casos bidimensional e tridimensional.

<p>The main goal of this thesis research is to expand the range of unique properties of phase transforming cellular materials (PXCMs), a new class of architected materials, and to extend their applicability both in the engineering disciplines and in the medical field. A novel aspect of PXCMs is their unique energy dissipation during loading via a snapping mechanism associated with a geometric transition between one stable configuration to another stable configuration at the unit cell level. Phase transformation is analogous to displacive transformations, such as martensitic transformations in shape memory alloys, with no change in configurational entropy. To accomplish this goal, three problem areas are addressed with the first exploring the effects of length scale as added structural hierarchy on material properties and energy dissipation, the second providing an analysis of the durability of architected materials via a novel additive manufacturing method, and the third, an extension into the medical field. Two examples are provided that demonstrate the effects of length scale as added structural hierarchy on material properties, and a machine learning approach for the feasible design of materials with additional levels of structural hierarchy is presented. A simple design approach coupled with a novel additive manufacturing method is discussed for the design of architected materials with high durability. Lastly, a concept for de-clogging bile stents via a temperature driven, shape-memory mechanism inspired by peristaltic locomotion in the human esophagus is presented.</p>

Titanium (Ti) foams of different densities 1622-4100 Kgm-3 made by a powder sintering technique were studied as to their structural and mechanical properties. The foams were tested under static and dynamic loading. The material was tested quasi statically and dynamically under strain rates in the range of 0.001-2500 s-1 and under different loading modes. It was found that strain rate sensitivity is more pronounced in lower density foams. Experiments were complimented by virtual testing. Based on the Voronoi tessellations a computational method was developed to generate stochastic foam geometries. Statistical control was applied to produce geometries with the microstructural characteristics of the tested material. The generated structures were numerically tested under different loading modes and strain rates. Voronoi polyhedrals were used to form the porosity network of the open cell foams. The virtually generated foams replicated the geometrical features of the experimentally tested material. Meshes for finite element simulations were produced. Existing material models were used for the parent material behaviour (sintered Ti) and calibrated to experiments. The virtual foam geometries of different densities were numerically tested quasi statically under uniaxial, biaxial and triaxial loading modes in order to investigate their macroscopic behaviour. Dynamic loading was also applied for compression. Strain rate sensitive and insensitive models were used for the parent material model in order to examine the influence of geometry and material strain rate sensitivity under high rates of deformation. It was found that inertial effects can enhance the strain rate sensitivity for low density foams and numerical predictions for the generated foam geometries were in very good agreement with experimental results. Power laws were established in scaling material properties with density. The study includes: 1. Information on the material behaviour and data for macroscopically modelling this type of foams for a range of densities and under different strain rates. 2. A proposed method for virtually generating foam geometries at a microscopic scale and examine the effect of geometrical characteristics on the macroscopic behaviour of foams.

Die vorliegende Dissertation beschäftigt sich mit der thermo-mechanischen Beschreibung und Bewertung von keramischen Filtern für die Metallschmelze-Filtration mithilfe der Finiten-Elemente-Methode. Infolge des zellularen Aufbaus des Werkstoffs handelt es sich um ein Mehrskalenproblem. Grundlegende Aufgaben der Arbeit waren deshalb die geometrische und mechanische Modellbildung sowie die Untersuchung verschiedener effizienzsteigernder Methoden zur Gewinnung einer akkuraten numerischen Lösung. Dabei wurden sowohl verschiedene Verfahren aus der Fachliteratur implementiert und kritisch bewertet, als auch neue Ansätze verfolgt. Die Untersuchungen konzentrierten sich auf das effektive elastische und elastisch-plastische Verhalten von Kelvin-, Weaire-Phelan- und Voronoi-Strukturen. Insbesondere die entwickelten Methoden und Werkzeuge zur automatisierten Modellbildung gestatten in einfacher Weise die Umsetzung von Parameterstudien und Optimierungsaufgaben. Aus darauf aufbauenden Sensitivitätsstudien wurden Empfehlungen hinsichtlich der geometrischen und mechanischen Modellbildung für zellulare Werkstoffe abgeleitet. Diese betreffen auch vielfach eingesetzte Methoden zur Modellreduktion für diese Werkstoffe und tragen somit zukünftig zu einer effizienteren Bewertung von Filterstrukturen bei.