The preliminary goal of this study is to determine the effects of processing conditions, compositions and microstructural morphologies of the constituents on the physical and thermo-mechanical properties of alumina (Al_2O_3) reinforced aluminum (Al) composites. Composites with 0, 5, 10, 20 and 25 vol% Al_2O_3 were manufactured using powder metallurgy method. The elastic properties (Young's and shear modulus) and the coefficient of thermal expansion (CTE) of the composites were determined using Resonant Ultrasound Spectroscopy (RUS) and Thermo Mechanical Analyzer (TMA) respectively at various temperatures. Increasing compacting pressure improved relative density (or lowered porosity) of the composites. Furthermore, increasing the Al_2O_3 vol% in the composite increased the elastic moduli and reduced the CTE of the composites. Increasing the testing temperature from 25 to 450 oC, significantly reduced the elastic moduli of the composites, while the CTE of the composites changed only slightly with temperatures. Secondly, the goal of this study is to determine the effect of microstructures on the effective thermo-mechanical properties of the manufactured Al-Al_2O_3 composites using finite element (FE) method. Software OOF was used to convert the SEM micrographs of the manufactured composites to FE meshed models, which were then used to determine the effective elastic modulus and CTE. It was observed that, effective modulus dropped by 19.7% when porosity increased by 2.3%; while the effective CTE was mildly affected by the porosity. Additionally, the effect of residual stress on the effective thermo-mechanical properties was studied, and the stress free temperature of the composites was determined. Another objective of this study is to examine the stress-strain response of Al-Al_2O_3 composites due to compressive loads at various temperatures. Elastic modulus, yield stress and strain hardening parameters were determined from the stress-strain curves and their dependency on temperature, porosity and volume fraction were studied. The experimental results were compared with the numerical results. It was observed that high-localized stresses were present near the pores and at the interfaces between Al and Al_2O_3 constituents. Finally, functionally graded materials (FGMs) with varying Al_2O_3 concentration (0, 5and 10 vol%) in Al were manufactured; and their stress-strain response and CTE were determined at various temperatures.

The law of bone remodeling, commonly referred to as Wolff's Law, asserts that the internal trabecular bone adapts to external loadings, reorienting with the principal stress trajectories to maximize mechanical efficiency, thereby creating a naturally optimum structure. The primary objective of the research was to utilize an advanced structural optimization algorithm, called design space optimization (DSO), to create a numerical framework to perform a micro-level three-dimensional finite element bone remodeling simulation on the human proximal femur and analyze the results to determine the validity of Wolff's hypothesis. DSO optimizes the layout of material by iteratively distributing it into the areas of highest loading, while simultaneously changing the design domain to increase computational efficiency. The result is a "fully stressed" structure with minimized compliance and increased stiffness. The large-scale computational simulation utilized a 175µm mesh resolution and the routine daily loading activities of walking and stair climbing. The resulting anisotropic human trabecular architecture was compared to both Wolff's trajectory hypothesis and natural femur data from the literature using a variety of visualization techniques, including radiography and computed tomography (CT). The remodeling predictions qualitatively revealed several anisotropic trabecular regions comparable to the natural human femurs. Quantitatively, the various regional bone volume fractions from the computational results were consistent with CT analyses. The strain energy proceeded to become more uniform during optimization; implying increased mechanical efficiency was achieved. The realistic simulated trabecular geometry suggests that the DSO method can accurately predict three-dimensional bone adaptation due to mechanical loading and that the proximal femur is an optimum structure as Wolff hypothesized. The secondary objective was to revise this computational framework to perform the first in-silico hip replacement considering micro-level bone remodeling. Two different commercially available hip prostheses were quantitatively analyzed using stress, strain energy, and bone mineral density as performance criteria and qualitatively visualized using the techniques above. Several important factors for stable fixation, determined from clinical evaluations, were evident: high levels of proximal bone loss, distal bone growth, and medial densification. The results suggest the DSO method can be utilized for comparative prosthetic implant stem design, uniquely considering post-operation bone remodeling as a design criterion. / Thesis (Master, Mechanical and Materials Engineering) -- Queen's University, 2010-08-16 15:30:55.144

The primary goals of the research in this dissertation are to perform a systematic study to identify and understand the fundamental cause of prolonged processing time during transient liquid phase bonding of difficult-to-bond single crystal Ni-base materials, and use the acquired knowledge to develop an effective way to reduce the isothermal solidification time without sacrificing the single crystalline nature of the base materials. To achieve these objectives, a multi-scale numerical modeling approach, that involves the use of a 2-D fully implicit moving-mesh Finite Element method and a Cellular Automata method, was developed to theoretically investigate the cause of long isothermal solidification times and determine a viable way to minimize the problem. Subsequently, the predictions of the theoretical models are experimentally validated. Contrary to previous suggestions, numerical calculations and experimental verifications have shown that enhanced intergranular diffusivity has a negligible effect on solidification time in cast superalloys and that another important factor must be responsible. In addition, it was found that the concept of competition between solute diffusivity and solubility as predicted by standard analytical TLP bonding models and reported in the literature as a possible cause of long solidification times is not suitable to explain salient experimental observations. In contrast, however, this study shows that the problem of long solidification times, which anomalously increase with temperature is fundamentally caused by departure from diffusion controlled parabolic migration of the liquid-solid interface with holding time during bonding due to a significant reduction in the solute concentration gradient in the base material. Theoretical analyses showed it is possible to minimize the solidification time and prevent formation of stray-grains in joints between single crystal substrates by using a composite powder mixture of brazing alloy and base alloy as the interlayer material, which prior to the present work has been reported to be unsuitable. This was experimentally verified and the use of the composite powder mixture as interlayer material to reduce the solidification time and avoid stray-grain formation during TLP bonding of single crystal superalloys has been reported for the first time in this research.

The exceptional properties of carbon nanomaterials make them ideal reinforcements for polymers. However, the main challenges in utilizing their unique properties are their tendency to form agglomerates, their non-controlled orientation, non-homogeneous distribution and finally the change in their shape/size due to processing. All the above are the result of the nanomaterial/polymer interfacial interactions which dictate the overall performance of the composites including the mechanical properties. The aforementioned uncertainties are the reason for the deviation observed between the experimentally determined properties and the theoretically expected ones. The focus of this study is to understand the reinforcing efficiency of carbon nanomaterials in polymers through finite element modeling that captures the effect of the interfacial interactions on the tensile modulus of polymer nanocomposites (PNCs). The novelty of this work is that the probability distribution functions of nanomaterials dispersion, distribution, orientation and waviness, determined through image analysis by extracting 3-D information from 2-D scanning electron micrographs, are incorporated into the finite element model allowing thus for fundamental understanding of how the nanostructure parameters affect the tensile modulus of the PNCs. The nanocomposites are made using melt mixing followed by either injections molding or melt spinning of fibers. Polypropylene (PP) is used as the polymer and carbon nanotubes (CNT) or exfoliated graphite nanoplatelets (xGnP) are used as nanoreinforcements. The presence of interphase, confirmed and characterized in terms of stiffness and width using atomic force microscopy, is also accounted for in the model. The dispersion and distribution of CNT within the polymer is experimentally altered by using a surfactant and by forcing the molten material to flow through a narrow orifice (melt spinning) that promotes alignment of CNT and even of the polymer chains along the flow/drawing direction. The effect of nanomaterials' geometry on the mechanical behavior of PNCs is also studied by comparing the properties of CNT/PP to those of xGnP/PP composites. Finally the reinforcing efficiency of CNT is determined independently of the viscoelastic behavior of the polymer by conducting tensile testing at temperatures below the glass transition temperature of PP. The finite element model with the incorporated image analysis subroutine has sufficient resolution to distinguish among the different cases (dispersion, distribution, geometry and alignment of nanomaterials) and the predicted tensile modulus is in agreement with the experimentally determined one. In conclusion, this study provides a tool, that integrates finite element modeling and thorough experiments that enables design of polymer nanocomposites with engineered mechanical properties.

The cohesive fracture of thin films is a concern for the reliability of many devices in microelectronics, MEMS, photovoltaics, and other applications. In microelectronic packaging the cohesive fracture toughness has become a concern with new low-k dielectric materials currently being used. To obtain the low-k values needed to meet electrical performance goals, the mechanical strength of the material has decreased. This has resulted in cohesive cracks occurring in the Back End of Line (BEoL) dielectric layers of the microelectronic packages. These cracks lead to electronic failures and occur after thermal loading (due to CTE mismatch of materials) and mechanical loading. To prevent these cohesive cracks, it is necessary to measure the cohesive fracture resistance of these thin films to implement during the design and analysis process. Many of the current tests to measure the cohesive fracture resistance of thin films are based on methods developed for larger scale specimens. These methods can be difficult to apply to thin films due to their size and require mechanical fixturing, physical contact near the crack tip, and complicated stress fields. Therefore, a fixtureless cohesive fracture resistance measurement technique has been developed that utilizes photolithography fabrication processes. This technique uses a superlayer thin film with a high intrinsic stress deposited on top of the desired test material to drive cohesive fracture through the thickness of test material. In addition to developing a technique to measure the fracture resistance of dielectric thin films, the use of carbon nanotube (CNT) forests as off-chip interconnects is investigated as a potential method to mitigate the fracture of these materials. The compressive and tensile modulus of CNT forests is characterized, and it is seen that the modulus is several orders of magnitude less than that of a single straight CNT. The low-modulus CNT forest will help mechanically decouple the chip from the board and reduce stress occurring in the dielectric layers as compared to the current technology of solder ball interconnects and therefore improve reliability. The mechanical performance of these CNT interconnects is investigated by creating a finite-element model of a flip chip electronic package utilizing CNT interconnects and comparing the chip stresses to a traditional solder ball interconnect scenario. Additionally, flip chips are fabricated with CNT forest interconnects, assembled to an FR4 substrate, and subjected to accelerated thermomechanical testing to experimentally investigate their performance.

The Formula SAE is a student based competition organised by SAE International where engineering students from a university design, develop and test a formula-style race car prototype to compete against other universities. The competition car needs to satisfy the competition rules set out by the organisers. The competition strives to stimulate original, creative problem solving together with innovative engineering design practices. In any race environment, the primary goal is always to be as competitive as possible. Due to the competitive nature of motor sport, vehicle components need to withstand various and severe stresses. The components of a race car vehicle are responsible for the vehicle’s handling characteristics and reliability. The chassis is a crucial and integral component of a Formula SAE competition car, primarily responsible for the vehicle’s performance characteristics. The chassis is the structural component that accommodates all the other components. A Formula SAE chassis is a structure that requires high torsional stiffness, low weight as well as the necessary strength properties. In this study, multiple Formula SAE chassis were designed and developed using computer aided design software. Each concept’s torsional stiffness, weight and strength properties were tested using finite element analysis software. The different concepts consisted of different design techniques and applications. All the concepts were analysed and assessed, leading to the identification of an acceptable prototype. The prototype was manufactured for experimental tests. The designed chassis complied with the Formula SAE rules and regulations. The weight, torsional stiffness and strength characteristics of the designed chassis frame were also favourable compared to accepted standards for Formula SAE chassis frames. The manufactured chassis was prepared for experimental tests in order to validate the simulation results produced by the finite element analysis. The torsional stiffness, weight and strength were experimentally determined and the results were compared with the corresponding simulations results. The comparison of the experimental and simulated results enabled the validation of the finite element analysis software. The study draws conclusions about the use of computer aided design and finite element analysis software as a design tool for the development of a Formula SAE chassis. Closure about the study is provided with general conclusions, recommendations and research possibilities for future studies. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2014

The primary goals of the research in this dissertation are to perform a systematic study to identify and understand the fundamental cause of prolonged processing time during transient liquid phase bonding of difficult-to-bond single crystal Ni-base materials, and use the acquired knowledge to develop an effective way to reduce the isothermal solidification time without sacrificing the single crystalline nature of the base materials. To achieve these objectives, a multi-scale numerical modeling approach, that involves the use of a 2-D fully implicit moving-mesh Finite Element method and a Cellular Automata method, was developed to theoretically investigate the cause of long isothermal solidification times and determine a viable way to minimize the problem. Subsequently, the predictions of the theoretical models are experimentally validated. Contrary to previous suggestions, numerical calculations and experimental verifications have shown that enhanced intergranular diffusivity has a negligible effect on solidification time in cast superalloys and that another important factor must be responsible. In addition, it was found that the concept of competition between solute diffusivity and solubility as predicted by standard analytical TLP bonding models and reported in the literature as a possible cause of long solidification times is not suitable to explain salient experimental observations. In contrast, however, this study shows that the problem of long solidification times, which anomalously increase with temperature is fundamentally caused by departure from diffusion controlled parabolic migration of the liquid-solid interface with holding time during bonding due to a significant reduction in the solute concentration gradient in the base material. Theoretical analyses showed it is possible to minimize the solidification time and prevent formation of stray-grains in joints between single crystal substrates by using a composite powder mixture of brazing alloy and base alloy as the interlayer material, which prior to the present work has been reported to be unsuitable. This was experimentally verified and the use of the composite powder mixture as interlayer material to reduce the solidification time and avoid stray-grain formation during TLP bonding of single crystal superalloys has been reported for the first time in this research.

There is no established method of measuring load accurately in a threaded connection at working temperatures exceeding 500°C. At these conditions conventional methods can not be used due to the sensitivity of the instruments and it is suggested that a non contact method should be used. The laser strain gauge was developed by the Loughborough University Optical Research Group and it is a non contact way of measuring surface strain. With the help of finite element analysis (FEA) a special nut was developed that can be used to measure the load on the connection by relating the surface strain of the nut to the load. Experimental work later revealed that due to the threads sticking in the connection there is hysteresis present between the load and surface strain relationship. To eliminate the hysteresis a new part was added to the connection which could be used to relate the surface strain on it to the load without any hysteresis. This new part was a specially designed washer with three grooves to allow easy access for the user to measure the surface strain using the laser strain gauge. Part of the design specification was that the load has to be determined to an accuracy of 0.5%. Using sensitivity analysis the washer was analysed in terms of how manufacturing imperfections affect the accuracy of the load measuring device. The results revealed that to achieve the required 0.5% accuracy the washer would have to be manufactured to very tight tolerances. To achieve these tight tolerances the manufacturing process would not be cost effective so it was proposed that individual calibration is required for each load measuring washer. Tests showed that with sufficient calibration the specially designed washer and the laser strain gauge can be combined and used as an accurate non contact load measuring device. As it is a non contact method it can be used in extreme environments including high temperatures. This thesis describes how background research, finite element analysis and experimental testing were used to develop the load measuring washer. Also it is shown, how in-depth sensitivity analysis was used to determine the accuracy of the prototype and that how manufacturing imperfections influence the working life of a threaded connection.

The thermal control of a die is crucial for the development of high efficiency injection moulds. For successful thermal management, this research provides an effective control strategy to find sensor locations, identify thermal dynamic models, and design controllers. By applying a clustering method and sensitivity analysis, sensor locations are identified. The neural network and finite element analysis techniques enable the modeling to deal with various cycle-times for the moulding process and uncertain dynamics of a die. A combination of off-line training through finite element analysis and training using on-line learning algorithms and experimental data is used for the system identification. Based on the system identification which is experimentally validated using a real system, controllers are designed using fuzzy-logic and self-adaptive PID methods with backpropagation (BP) and radial basis function (RBF) neural networks to tune control parameters. Direct adaptive inverse control and additive feedforward control by adding direct adaptive inverse control to self-adaptive PID controllers are also provided. Through a comparative study, each controller’s performance is verified in terms of response time and tracking accuracy under different moulding processes with multiple cycle-times. Additionally, the improved cooling effectiveness of the conformal cooling channel designed in this study is presented by comparing with a conventional straight channel.

Cold metal forming processes have been widely used for manufacturing of their high production rates and increased yield strength after forming process. For the use in service, increased yield strength of the cold-formed products should be known. The new yield strength can be found by several methods. Mechanical tests such as compression or tensile test are direct methods to obtain new yield strength if the product shape is appropriate. Finite element simulations may be another way to get accurate results for new yield strength distribution. Also Vickers hardness number can be used for prediction of yield strengths by available conversion models. The aim of this study is to compare the results of all these methods. During the study two different materials (austenitic stainless steel and carbon steel) cold formed by drawing and extrusion are investigated. FE simulations have been conducted to predict product properties. For this purpose flow curves obtained from compression and tensile tests are used in FE-models based on elasto-plastic, isotropic hardening material. Results show that both materials are highly anisotropic and have much lower yield strength values than found in simulations. Similarly none of the models correlating Vickers hardness numbers and yield strengths are successful since they are designed for an isotropic hardening material. This study basically presents the deviation of a real material behavior from isotropic material behavior.