In this work, we sought to provide a deeper understanding of the energy-absorbing capabilities of cast lattice structures. These structures absorb large amounts of energy via plastic deformation, but their most attractive characteristic from a structural standpoint is the favorable energy absorption-to-weight ratio. Conventional machining techniques are not well suited for manufacturing such complex features; therefore, we combined additive manufacturing (AM) with a well-known understanding of the metalcasting process. We used AM to produce sand molds in different sizes and with additional features for various applications — these molds were then filled with molten metal. Current literature suggests that this when appropriately applied, this methodology results in complex geometries castings comparable properties to parts made with traditionally produced sand molds. We chose to study periodic lattice structures for their repeatability and subsequent ease of making predictions via computer simulations. We first produced lightweight cast metal-ceramic composite panels of 225 x 225 x 60 mm. Our AM molds included provisions to install ceramic or hard metal tiles before pouring the molten metal. The tiles were encapsulated in the final casting to yield a composite structure. The initial material selection consisted of an aluminum A356-T6 alloy matrix with silicon carbide tiles. The composite lattice structures were tested against high-velocity projectiles — 0.30 caliber armor-piercing (AP M2) and NATO 7.62 mm ball rounds. We anticipated that the metal matrix alone would not be able to defeat these threats. However, the panels did reduce the striking velocity by approximately 20%. The thickness of the ceramic tiles varied from 4 mm to 8 mm at 2 mm increments. As expected, the hard ceramic tiles proved effective at improving the penetration resistance of the composite lattice structures — the impacts on regions with 4 mm thick tiles resulted in the reduction of striking velocity up to 49%; moreover, as the thickness was increased to 8 mm, the panels defeated the projectiles. We used these results to produce and validate a finite element (FE) model capable of replicating the experimental data within 5%. This model was later used to study how the ceramic material interacts with the lattice to absorb large amounts of kinetic energy from incident projectiles. Following, we manufactured smaller versions of these panels—50 x 50 x 90 mm test specimens for uniaxial compression testing for this instance. Once again, we relied on the capabilities of the FE method to replicate the test results within 10% for peak load and maximum displacement. We utilized computer simulations to optimize the design of the lattice structure. Its energy-absorbing capabilities were improved significantly — in this case, a 30% increase in the specific internal energy (internal energy per unit mass) as the evaluating criteria. The FE model was also used to study the performance of several other truss topologies. Lastly, we used computer simulations to evaluate the feasibility of making these cast lattice structures with ferrous alloys. We chose to work with Fe30Mn4Al0.9C due to its lower density and higher toughness than other steel grades. The first challenge was the lack of thermophysical property data in the literature for this alloy system. Hence, we used the CALPHAD method to calculate all the datasets needed to perform the mold filling and solidification simulation. Several of these calculations were validated experimentally. The location and severity of porosity between the model and the casting were in good agreement. / Doctor of Philosophy / The advent of additive manufacturing (AM), commonly known as 3D printing is a group of different digital-era technologies that has facilitated the production of complex designs that are not feasible to manufacture using conventional techniques. In the realm of metallic components one such technique involves the use of a laser beam to consolidate metallic powders via a layer-by-layer deposition process. Despite its advantages, this process has unique challenges, such as limited material selection and relatively small part volume. In this work, we have employed a hybrid approach that combines the use of AM with expertise in metalcasting to produce lightweight components with complex geometries. We used 3D printed sand molds that are then filled with molten metal of different alloy systems such as aluminum and steel. At first, we incorporate hard ceramic materials to increase the performance of the final parts under ballistics testing. Our aim is to upscale the size of current designs such that these devices can be used in various applications that require high absorption of kinetic energy, and that are lightweight and easy to replace.

Achieving light weight armor design has become an important engineering challenge in the last three decades. As weapons becoming highly sophisticated, so does the ammunition, potential targets have to be well protected against such threats. In order to provide mobility, light and effective armor protection materials should be used. In this thesis, numerical simulation of the silicon carbide armor backed by KevlarTM composite and orthogonally impacted by 7.62mm armor piercing (AP) projectile at an initial velocity of 850 m/s is analyzed by using AUTODYN hydrocode. As a first step, ceramic material behavior under impact conditions is validated numerically by comparing the numerical simulation result with the test result which is obtained from the literature. Then, different numerical simulations are performed by changing the backing material thickness, i.e. 2, 4, 6 and 8mm, while the thickness of the ceramic is held constant, i.e. 8mm. At the end of the simulations, optimum ceramic/composite thickness ratio is sought. The results of the simulations showed that for the backing thickness values of 4, 6 and 8mm, the projectile could not perforate the armor system. On the contrary, the projectile could penetrate and perforate the armor system for the backing thickness value of 2mm and it has still some residual velocity. From these results, it is inferred that the optimum ceramic/composite thickness ratio is equal to about 2 for the silicon carbide and kevlar configuration.

The introduction of ceramics into the market of wood cutting tools has failed so far due to the generally low toughness of ceramics which is causing brittle failure of the cutting edge. A feasibility study showed that Si3N4/SiC composites with fine elongated β-Si3N4 grains are a promising material for industrial wood machining and outperform commercial standard tungsten carbide tools in terms of lifetime. However, they were produced by hot pressing followed by very costly diamond cutting and grinding. The costs associated with the above production route are too high for an industrial viability. In this thesis Si3N4/SiC composites suitable for industrial wood milling are produced by a near net shape processing route including gas pressure sintering. These newly developed tools show less abrasive wear and consequently twice as long lifecycles than commercial standard tungsten carbide tools. Microscopic properties determine the performance of the Si3N4/SiC cutting tools. Therefore, an adequate selection of sintering additives is crucial. 12 wt% sintering additives are included in the composite as a combination of Al2O3 and the refractory oxides La2O3 and Y2O3. Important for the production of effective Si3N4/SiC wood cutting tools is the formation of a partly crystalline silicate phase within the multiple grain junctions during the final treatment by hot isostatic pressing. The use of MgO as a sintering additive for facilitating the densification of the Si3N4 ceramics inhibits the formation of the favourable silicate phase and must be avoided for the production of these wood cutting tools.

No description available.

The aim of this study was to understand the processing – structure – property relationships in spark plasma sintered (SPS) boron carbide (B4C) and B4C-titanium diboride (TiB2) ceramic composites. SPS allowed for consolidation of both B4C and B4C-TiB2 composites without sintering additives, residual phases, e.g., graphite, and excessive grain growth due to long sintering times. A selection of composite compositions in 20% TiB2 feedstock powder increments from 0% to 100%, was sintered at 1900°C for 25 minutes hold time. A homogeneous B4C-TiB2 composite microstructure was determined with excellent distribution of TiB2 phase, while achieving ~99.5% theoretical density. An optimum B4C-23 vol.% TiB2 composite composition with low density of ~3.0 g/cm3 was determined that exhibited ~30-35% increase in hardness, fracture toughness, and flexural bend strength compared to commercial armor-grade B4C. This is a result of a) no residual graphitic carbon in the composites, b) interfacial microcrack toughening due to thermal expansion coefficient differences placing the B4C matrix in compression and TiB2 phase in tension, and c) TiB2 phase aids in crack deflection thereby increasing the amount of intergranular fracture. Collectively, the addition of TiB2 serves as a strengthening and toughening agent, and SPS shows promise for the manufacture of hybrid ceramic composites.

No description available.

Dans cette étude de doctorat, de la poudre de Y3Al5O12 (YAG) a été synthétisé avec plusieurs méthodes: atomisation, synthèse de réaction et co-précipitation. Le procédé de synthèse le plus prometteur, la co-précipitation, a été optimisé pour obtenir une poudre hautement frittable, présentant une phase pure. Le traitement approprié avant frittage, comprenant calcination, efficace dispersion et séchage homogène, a été réalisé. La poudre de YAG a été dispersée avec plusieurs méthodes, avant frittage. Grâce à la technique Spark Plasma Sintering (SPS) une évaluation très rapide de l'influence des différents traitements a été réalisée. Il a été constaté que, pour une poudre obtenue avec une telle synthèse, la méthode de dispersion est cruciale afin de obtenir une transparence élevée du materiaux fritté. En raison de l'aptitude au frittage de la poudre, du traitement approprié avant frittage et de la basse température du cycle effectué par SPS, un matériau à grains fins a été obtenu. Des mesures de spectroscopie de photoélectrons (XPS) ont été effectuées sur la poudre de YAG et sur le matériaux fritté, et plusieurs differences ont été mises en évidence. Quelques hypothèses ont été faites pour expliquer les differences observées, et certains preuves supplémentaires pour les vérifier ont été mises en avant. Une poudre composite alumine-zircone-YAG a été synthétisé à partir d'une poudre d'alumine commerciale, qui a été fonctionnalisé avec chlorures de yttrium et de zirconium. Les traitements de pré-frittage appropriées ont été effectués, comprenant une calcination à basse température et une calcination "rapide", pour favoriser la germination des petits cristallites. Deux méthodes de mise en forme, coulage et pressage, ont été réalisées. Il a été constaté que le coulage permet la production de matériaux céramiques beaucoup plus homogènes. Une caractérisation mécanique préliminaire a été effectuée. Une caractérisation spectroscopique des poudres d'alumine-YAG, traités à basse et haute température, a été réalisée. Il a été mis en évidence que l'état d'hydratation des poudres varie avec la fonctionnalisation par les chlorures. La présence de sites Y sur la surface des poudres composites a été mise en évidence par XPS et à partir des spectres infrarouges (spectroscopie infrarouge par transformée de Fourier, FTIR) des échantillons soumis à des différentes pressions de monoxide de carbone (CO). / In this PhD study, Yttrium aluminum garnet (Y3Al5O12, YAG) powder was synthesised with several methods, i.e. spray drying, reaction synthesis and co-precipitation. The most promising synthesis method, i.e. co-precipitation, was optimized to obtain a pure phase, highly sinterable powder. The appropriate pre-sintering processing, i.e. calcination treatment, e fficient dispersion, homogeneous drying, were performed. YAG powder was dispersed with several methods, prior to sintering. Through Spark Plasma Sintering (SPS) a very fast assessment of the influence of the various treatments was performed. It was found that, for the synthesised powder, the dispersion method is crucial to obtain a high transparency. Due to the high sinterability of the powder and to the appropriate pre-sintering treatment, a low temperature SPS cycle was performed, and a fine-grained material was obtained. X-ray Photoelectron Spectroscopy (XPS) measurements were performed on YAG powder and on the sintered material, and several di fferences were evidenced. Some hypothesis were made to explain the observed di fferences, and some additional proofs to verify them were put forward. A composite Alumina-YAG-Zirconia powder was synthesized, starting from a commercial alumina powder, which was functionalised with Yttrium and Zirconium chlorides. The appropriate pre-sintering treatments were performed, comprising a low temperature calcination and a "fast" calcination, to favour the germination of small crystallites. Two shaping methods, i.e. slip casting and pressing, were performed. It was found that slip casting allows the production of much more homogeneous ceramic materials. A preliminary mechanical characterization was performed. A spectroscopic characterization of Alumina-YAG powders, heat-treated at low and high temperatures, was performed. It was evidenced that the hydration state of the powders changes with chlorides functionalization. The presence of Y sites on the surface of the composite powders was evidenced by X-ray Photoelectron Spectroscopy and from the di fference spectra of powdered samples subjected to various CO pressures.

L'objectif de cette thèse était de développer et de caractériser la microstructure et les propriétés mécaniques des céramiques bio-inspirées. L'alumine inspirée par la nacre fabriquée par texturation à la glace (freeze-casting), précédemment développée dans le cadre de la thèse de F. Bouville, a été choisie comme matériau de référence. La simplification et le changement d’échelle du procédé d’élaboration des matériaux ont été étudiés. Le procédé sophistiqué de freeze-casting a été remplacé par le pressage uniaxial à cru. Les mesures de diffraction des électrons rétrodiffusés ont confirmé le bon alignement après frittage des plaquettes d'alumine utilisées pour préparation du matériau. Le cycle de frittage assisté par effet de champs a été adapté à de plus grandes quantités de poudre céramique et d'additifs organiques. La deuxième partie du projet a été consacrée à la modification de l'interphase entre les plaquettes d'alumine, afin d’améliorer les propriétés mécaniques du matériau. Diverses possibilités ont été explorées: ajout de poudre de zircone, dépôt de zircone sur les plaquettes par réaction sol-gel ou substitution de la phase vitreuse par du graphène. Tous les matériaux obtenus ont été caractérisés par flexion quatre points sur des barrettes entaillées. La troisième partie de cette étude a porté sur le développement de composites multicouches métal/céramique, par frittage simultané d'alumine et de titane. L'épaisseur et la composition de la feuille de titane ont été modifiées pour étudier leur influence sur les phénomènes de diffusion lors du frittage. Les composites ont été caractérisés par MEB, EBSD, spectroscopie à rayons X à dispersion d'énergie et tomographie à rayons X au synchrotron. La fabrication simplifiée des matériaux permet de préparer des échantillons de plus grandes dimensions de céramiques inspirées par la nacre, sans passer par une étape de freeze-casting. Cependant, la croissance des grains doit être limitée pour maintenir de bonnes propriétés mécaniques. La modification de l'interphase entre les plaquettes d'alumine n'a pas amélioré les propriétés mécaniques des matériaux par rapport au matériau de référence. D'autre part, le dépôt de nano-zircone sur la surface des plaquettes semble prometteur et devrait faire l'objet d'études plus poussées. Dans le cas des composites alumine/titane, les composites architecturées multiéchelles ont été fabriqués de manière assez simple. Cependant, il est crucial d'éviter la fissuration des feuilles de métal afin d’améliorer les propriétés mécaniques. / The goal of this thesis was to develop and characterize the microstructure and the mechanical properties of bioinspired ceramic composites. Nacre-like alumina fabricated by freeze-casting previously developed in Bouville thesis was chosen as a reference material. Simplifying and up-scaling material fabrication was intended. Architectural levels were added to the microstructure to further improve mechanical properties of the material. Sophisticated processing by freeze-casting was substituted by uniaxial pressing. Electron backscatter diffraction observations confirmed the good alignment of alumina platelets used to prepare the material. The field assisted sintering cycle was adapted to greater quantities of ceramic powder and organic additives. The second part of the project was dedicated to the modification of the interphase between alumina platelets. Various possibilities were explored: adding fine zirconia powder, depositing zirconia on the platelets by sol-gel reaction, or substituting the glassy phase by graphene. All obtained materials were characterized by four point bending on notched bars. The third part of this study was focused on the development of multilayered metal/ceramic composites, by simultaneous sintering of alumina and titanium. The titanium foil thickness and composition were varied. The composites were characterized by SEM, EBSD, energy dispersive X-ray spectroscopy and synchrotron X-ray tomography. Detailed microstructural and chemical characterization was performed to understand mechanisms of titanium diffusion into ceramic matrix. Simplified material fabrication allows to prepare larger samples of nacre-like ceramics. However grain growth should be limited to maintain good mechanical properties. Modification of the interphase between alumina platelets did not improve mechanical properties of the materials as compared to the reference material. On the other hand, depositing nano-zirconia on platelets surface seems promising and should be further investigated. In case of alumina/titanium composites, a multiscale architecture composites were process in a rather simple way. However, avoiding metal foil cracking is crucial to improve mechanical properties.

Neste trabalho é apresentado um procedimento para a análise modal de compósitos. Uma revisão da literatura a este respeito revela que os procedimentos usualmente empregados para este fim baseiam-se em métodos por balanço de massa, análise de imagem ou por análise ponto-a-ponto. Os métodos de análise modal por balanço de massa se baseiam na determinação da composição química da amostra e no conhecimento prévio da composição de cada fase para, então, proceder à determinação da concentração das fases resolvendo um sistema de equações lineares. Isto, no entanto, nem sempre é possível, especialmente quando as composições químicas de mais de uma fase são semelhantes. Os métodos por análise de imagem utilizam de diferentes contrastes para diferenciar as fases de uma amostra e, a partir da área ocupada por cada uma delas, estimar sua fração em volume. Estes métodos estão sujeitos a interpretações incorretas dos tons de cinza das imagens obtidas, o que pode ser contornado utilizando-se imagens resultantes do mapeamento de elementos por fluorescência de raios X, ao custo de um maior tempo de aquisição. O método proposto neste trabalho faz uso da técnica de contagem de pontos com a identificação automática das fases, a partir de seus espectros de fluorescência de raios X, por meio de uma rede neural previamente treinada. A quantidade de cada fase é estimada a partir da frequência com a qual ela é identificada em diferentes pontos da amostra. A precisão da análise pode ser controlada de acordo com o número de pontos analisados. O procedimento de análise ponto-a-ponto foi quase inteiramente automatizado. A análise dos dados é realizada por um programa ("Sherlock") desenvolvido para esta finalidade. Para avaliação do procedimento proposto, foram analisadas amostras de compósitos cerâmicos e um compósito metálico. A partir destas análises foi possível avaliar a precisão e algumas das limitações do método, que se mostrou comparável à técnica de mapeamento de elementos por fluorescência de raios X. O método proposto apresenta ainda a versatilidade da inclusão de outras fontes de informações acerca das fases que compõem a amostra, tais como micro-Raman e micro-FTIR, facilitando assim a sua expansão para a inclusão de fases orgânicas na análise modal de materiais compósitos. / Submitted by Marcelo Teixeira (mvteixeira@ucs.br) on 2014-05-14T18:47:08Z No. of bitstreams: 1 Dissertacao Felipe G Pandolfo.pdf: 2368255 bytes, checksum: 92253593dc32d9f87309283b10c7eac7 (MD5) / Made available in DSpace on 2014-05-14T18:47:08Z (GMT). No. of bitstreams: 1 Dissertacao Felipe G Pandolfo.pdf: 2368255 bytes, checksum: 92253593dc32d9f87309283b10c7eac7 (MD5) / A modal analysis procedure for composites is presented in this work. Procedures employed to aim this objective can be divided into three groups: mass-balance, image analysis and point-counting. The mass-balance methods are based on the determination of the chemical composition of the sample and on the prior knowledge of the composition of each phase, so to determine the phase concentration by solving a matrix of linear equations. Unfortunately, sometimes it is not possible, specially when two or more phases presentes similar compositions. Image analysis is done using different contrast settings to dicriminate phases and to estimate its volume fraction, based on the area filled by each one. The method may lead to wrong results due to overlapping grey levels. One may employ x-ray fluorescence maps to avoid such errors, although the technique is often very slow. The procedure proposed in this work uses the point-counting method with an automated phase identification, using x-ray spectral data, by means of a formerly trainned neural network. The phase quantities are estimated from the identification frequency of each phase in several points of the sample. The precision of the analysis can be controlled by the number of acquisition points. Almost all procedure has been automated. Data analysis is performed by a software ("Sherlock") developed for this purpose. To evaluate the proposed procedure, ceramic composite samples and a metal composite sample were analysed. These analyses supported the precision evaluation and some limitations of the technique, which may be compared to X-ray element mapping. Further, the proposed procedure can deal with other sources of phase data, making it easy to include organic phase identification into the modal analysis of composite material.

Neste trabalho é apresentado um procedimento para a análise modal de compósitos. Uma revisão da literatura a este respeito revela que os procedimentos usualmente empregados para este fim baseiam-se em métodos por balanço de massa, análise de imagem ou por análise ponto-a-ponto. Os métodos de análise modal por balanço de massa se baseiam na determinação da composição química da amostra e no conhecimento prévio da composição de cada fase para, então, proceder à determinação da concentração das fases resolvendo um sistema de equações lineares. Isto, no entanto, nem sempre é possível, especialmente quando as composições químicas de mais de uma fase são semelhantes. Os métodos por análise de imagem utilizam de diferentes contrastes para diferenciar as fases de uma amostra e, a partir da área ocupada por cada uma delas, estimar sua fração em volume. Estes métodos estão sujeitos a interpretações incorretas dos tons de cinza das imagens obtidas, o que pode ser contornado utilizando-se imagens resultantes do mapeamento de elementos por fluorescência de raios X, ao custo de um maior tempo de aquisição. O método proposto neste trabalho faz uso da técnica de contagem de pontos com a identificação automática das fases, a partir de seus espectros de fluorescência de raios X, por meio de uma rede neural previamente treinada. A quantidade de cada fase é estimada a partir da frequência com a qual ela é identificada em diferentes pontos da amostra. A precisão da análise pode ser controlada de acordo com o número de pontos analisados. O procedimento de análise ponto-a-ponto foi quase inteiramente automatizado. A análise dos dados é realizada por um programa ("Sherlock") desenvolvido para esta finalidade. Para avaliação do procedimento proposto, foram analisadas amostras de compósitos cerâmicos e um compósito metálico. A partir destas análises foi possível avaliar a precisão e algumas das limitações do método, que se mostrou comparável à técnica de mapeamento de elementos por fluorescência de raios X. O método proposto apresenta ainda a versatilidade da inclusão de outras fontes de informações acerca das fases que compõem a amostra, tais como micro-Raman e micro-FTIR, facilitando assim a sua expansão para a inclusão de fases orgânicas na análise modal de materiais compósitos. / A modal analysis procedure for composites is presented in this work. Procedures employed to aim this objective can be divided into three groups: mass-balance, image analysis and point-counting. The mass-balance methods are based on the determination of the chemical composition of the sample and on the prior knowledge of the composition of each phase, so to determine the phase concentration by solving a matrix of linear equations. Unfortunately, sometimes it is not possible, specially when two or more phases presentes similar compositions. Image analysis is done using different contrast settings to dicriminate phases and to estimate its volume fraction, based on the area filled by each one. The method may lead to wrong results due to overlapping grey levels. One may employ x-ray fluorescence maps to avoid such errors, although the technique is often very slow. The procedure proposed in this work uses the point-counting method with an automated phase identification, using x-ray spectral data, by means of a formerly trainned neural network. The phase quantities are estimated from the identification frequency of each phase in several points of the sample. The precision of the analysis can be controlled by the number of acquisition points. Almost all procedure has been automated. Data analysis is performed by a software ("Sherlock") developed for this purpose. To evaluate the proposed procedure, ceramic composite samples and a metal composite sample were analysed. These analyses supported the precision evaluation and some limitations of the technique, which may be compared to X-ray element mapping. Further, the proposed procedure can deal with other sources of phase data, making it easy to include organic phase identification into the modal analysis of composite material.