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The focus of this research is characterizing a new material system composed of carbon and graphite foams, which has potential in a wide variety of applications encompassing aerospace, military, offshore, power production and other commercial industries. The benefits of this new material include low cost, light weight, fire-resistance, good energy absorption, and thermal insulation or conduction as desired. The objective of this research is to explore the bulk material properties and failure modes of the carbon foam through experimental and computational analysis in order to provide a better understanding and assessment of the material for successful design in future applications. Experiments are conducted according to ASTM standards to determine the mechanical properties and failure modes of the carbon foam. Sandwich beams composed of open cell carbon foam cores and carbon-epoxy laminate face sheets are tested in the flexure condition using a four point setup. The primary failure mode is shear cracks developing in the carbon foam core at a critical axial strain value of 2,262 με. In addition to flexure, the carbon foam is loaded under tensile and shear loads to determine the respective material moduli. Computational analysis is undertaken to further investigate the carbon foam's failure modes and material characteristics in the sandwich beam configuration. Initial estimates are found using classical laminated plate theory and a linear finite element model. Poor results were obtained due to violation of assumptions used in both cases. Thus, an additional computational analysis incorporating three dimensional strain-displacement relationships into the finite element analysis is used. Also, a failure behavior pattern for the carbon foam core is included to simulate the unique failure progression of the carbon foam on a microstructure level. Results indicate that displacements, strains and stresses from the flexure experiments are closely predicted by this two parameter progressive damage model. The final computational model consisted of a bond line (interface) study to determine the source of the damage initiation, and it is concluded that damage initiates in the carbon foam, not at the bond line.

The focus of this research is characterizing a new material system composed of carbon and graphite foams, which has potential in a wide variety of applications encompassing aerospace, military, offshore, power production and other commercial industries. The benefits of this new material include low cost, light weight, fire-resistance, good energy absorption, and thermal insulation or conduction as desired. The objective of this research is to explore the bulk material properties and failure modes of the carbon foam through experimental and computational analysis in order to provide a better understanding and assessment of the material for successful design in future applications. Experiments are conducted according to ASTM standards to determine the mechanical properties and failure modes of the carbon foam. Sandwich beams composed of open cell carbon foam cores and carbon-epoxy laminate face sheets are tested in the flexure condition using a four point setup. The primary failure mode is shear cracks developing in the carbon foam core at a critical axial strain value of 2,262 με. In addition to flexure, the carbon foam is loaded under tensile and shear loads to determine the respective material moduli. Computational analysis is undertaken to further investigate the carbon foam's failure modes and material characteristics in the sandwich beam configuration. Initial estimates are found using classical laminated plate theory and a linear finite element model. Poor results were obtained due to violation of assumptions used in both cases. Thus, an additional computational analysis incorporating three dimensional strain-displacement relationships into the finite element analysis is used. Also, a failure behavior pattern for the carbon foam core is included to simulate the unique failure progression of the carbon foam on a microstructure level. Results indicate that displacements, strains and stresses from the flexure experiments are closely predicted by this two parameter progressive damage model. The final computational model consisted of a bond line (interface) study to determine the source of the damage initiation, and it is concluded that damage initiates in the carbon foam, not at the bond line.

In order to remain competitive in the global market businesses are under ever increasing pressure to ramp up production rates whilst simultaneously improving cost effectiveness to allow continued profitable growth. This requirement is particularly challenging in high value manufacturing which is characterised by expensive product and manufacturing systems and relatively low production volume. This thesis introduces a method for the design of robust and reliable manufacturing processes through the prevention of identified potential failure modes that is based on the principles of the existing Failure Mode Avoidance framework used for automotive system design. The tools and techniques that exist in the literature are reviewed in order to understand the best practice, and subsequently a Manufacturing Failure Mode Avoidance framework is designed. This framework is demonstrated through two unique case studies conducted in a real life manufacturing environment in order to validate its appropriateness to provide robust countermeasures to failure which will allow right first time manufacture. The outcomes of the implementations are discussed, conclusions drawn and opportunities for further research are provided.

The condition of water and wastewater pipelines has been deteriorating with time and since this infrastructure is out-of-sight, the assessment has been neglected over the years. The advancement of technology in various fields has provided pathway for development of several technologies for assessment of the condition of pipeline systems. However, there is no standard guidance or tool for the utilities to use these technologies appropriately. The utilities are unaware of the present state-of- the- art technologies. The predictability and condition assessability indices will help utilities predict a probable failure and take steps to prevent it. The predictability index will indicate the inherent, theoretical predictability of key types of pipe failures. The pipe failure predictability index would be a score calculated by identifying high priority pipe types, characterizing their failure modes, mechanism, conditions, and indicators, reliability of indicators, lead-time of the indicators, and other factors. The condition assessability index will indicate the technical and economical methods of preventing key types of pipe failures. The pipe failure condition assessability index is similar to the predictability index, but it takes into account the capability of existing inspection technologies for measuring the required failure indicator parameters. Prestressed Concrete Cylinder Pipes are used in large diameter water pipelines throughout the United States to convey large volumes of water. Prestressed Concrete Cylinder Pipes are complex composite pipes. Therefore, prediction and prevention of failure of these pipelines is complex and requires a better understanding of the system. This research concentrates around development of Predictability and Condition Assessability Indices for PCCP pipelines. / Master of Science

Survival analysis is applied on mechanical components installed in gas turbines. We use field experience data collected from repair inspection reports. These data are highly censored since the exact time-to-event is unknown. We only know that it lies before or after the repair inspection time. As event we consider irreparability level of the mechanical components. The aim is to estimate survival functions that depend on the different environmental attributes of the sites where the gas turbines operate. Then, the goal is to use this information to obtain optimal time points for preventive maintenance. Optimal times are calculated with respect to the minimization of a cost function which considers expected costs of preventive and corrective maintenance. Another aim is the investigation of the effect of five different failure modes on the component lifetime. The methods used are based on the Weibull distribution, in particular we apply the Bayesian Weibull AFT model and the Bayesian Generalized Weibull model. The latter is preferable for its greater flexibility and better performance. Results reveal that components from gas turbines located in a heavy industrial environment at a higher distance from sea tend to have shorter lifetime. Then, failure mode A seems to be the most harmful for the component lifetime. The model used is capable of predicting customer-specific optimal replacement times based on the effect of environmental attributes. Predictions can be also extended for new components installed at new customer sites.

Nesta tese, apresenta-se um modelo de confiabilidade estatística para aplicação em dados de vida de um produto, buscando classificar três modos de falhas distintos associados à ocorrência de falhas prematuras, aleatórias e por desgaste. A ocorrência dos três modos de falhas segue os princípios de aplicação dos modelos teóricos por riscos concorrentes e seccionais. O modelo proposto utiliza duas distribuições de Weibull, com dois e três parâmetros, e uma distribuição exponencial. A distribuição de Weibull com dois parâmetros tem por objetivo representar os modos de falhas prematuras: a distribuição de Weibull com três parâmetros busca capturar os modos de falhas por desgaste; a distribuição exponencial mede a ocorrência de falhas aleatórias decorrentes de uso operacional de um produto. Considera-se que falhas prematuras e por desgaste ocorram seqüencialmente, enquanto falhas aleatórias ocorram de forma concorrente às falhas prematuras e por desgaste tão logo o produto seja colocado em operação. Para dimensionar o número de ocorrências vinculadas aos três modos de falhas são utilizados dados coletados durante o período de garantia e pós-garantia. Os dados de garantia são registros históricos do produtor e os dados da pós-garantia referem-se a informações obtidas de especialistas, já que dados após a garantia apresentam elevado nível de censura. Equações de confiabilidade e estimadores de máxima verossimilhança são apresentados para definir o perfil e os parâmetros do modelo proposto. Um estudo de caso com dados coletados de um equipamento elétrico-eletrônico subsidia a aplicação do modelo enquanto que um teste estatístico de ajuste de dados é utilizado para validar o referido modelo. / This thesis presents a reliability model for product life data presenting three different failure modes, associated with early, random and wear-out failures. The model is based on theoretical concepts related to competing risk and sectional models. The proposed model is structured based on two Weibull distributions, with two and three parameters, and one exponential distribution. The Weibull distribution with two parameters is aimed at modeling early failure modes; the Weibull distribution with three parameters models wear-out failure modes; the exponential distribution models random failures due to operational use. It is considered that early and wearout failures take place one after the other while random failures occur at the same time as early and wear-out failures as soon as the product starts operating. To measure each period related to the three failure modes, data from warranty and post-warranty periods are used. Warranty data are historical records; post-warranty data are gathered from experts, and are aimed at decreasing the degree of censoring in the data. Once the model is defined, reliability figures and maximum likelihood estimators are derived. Real data obtained from warranty claims on electricelectronic equipments are used to illustrate the developments proposed and a goodness-of-fit test is used to validate the performance of this model.

The application of advanced composite materials, such as graphite/epoxy, has been on the rise for the last four decades. The mechanical advantages, such as their higher specific stiffness and strength as compared to monolithic materials, make them attractive for aerospace and automotive applications. Despite these advantages, composites with brittle fibers have lower ductility and fracture toughness than monolithic materials. One way to increase the fracture toughness of composites is to have a weak fiber-matrix interface that would blunt crack tips by crack deflection into the interface and hence enhance fracture toughness. However, this also reduces the transverse properties of the composite. Therefore, an optimum fiber-matrix interface would be the one that is just weak enough to cause crack deflection into interface. This study investigates the effect of fiber-to-matrix moduli ratio, fiber-volume fraction, fiber orthotropy, and thermal stresses on the possibility of crack deflection. A finite element model is used to analyze a 2-D axisymmetric representative volume element- a three-phase composite cylinder made of fiber, matrix, and composite. A penny shaped crack is assumed in the fiber. To determine whether the crack would deflect into the interface or propagate into the matrix, maximum stresses at the fiber-matrix interface and in the matrix are compared to the interface and matrix strengths. As opposed to most studies in the literature, this study found that fiber-volume fractions do have an impact on crack deflection and this impact increases with large fiber-to-matrix moduli ratios. The presence of orthotropic fiber in the composite increases the possibility of crack deflection with increasing fibervolume fraction in the early and middle stages of the fiber crack growth. The thermal stresses decrease the likelihood of crack deflection when the thermal expansion coefficient of the matrix is larger than that of the fiber.

Nesta tese, apresenta-se um modelo de confiabilidade estatística para aplicação em dados de vida de um produto, buscando classificar três modos de falhas distintos associados à ocorrência de falhas prematuras, aleatórias e por desgaste. A ocorrência dos três modos de falhas segue os princípios de aplicação dos modelos teóricos por riscos concorrentes e seccionais. O modelo proposto utiliza duas distribuições de Weibull, com dois e três parâmetros, e uma distribuição exponencial. A distribuição de Weibull com dois parâmetros tem por objetivo representar os modos de falhas prematuras: a distribuição de Weibull com três parâmetros busca capturar os modos de falhas por desgaste; a distribuição exponencial mede a ocorrência de falhas aleatórias decorrentes de uso operacional de um produto. Considera-se que falhas prematuras e por desgaste ocorram seqüencialmente, enquanto falhas aleatórias ocorram de forma concorrente às falhas prematuras e por desgaste tão logo o produto seja colocado em operação. Para dimensionar o número de ocorrências vinculadas aos três modos de falhas são utilizados dados coletados durante o período de garantia e pós-garantia. Os dados de garantia são registros históricos do produtor e os dados da pós-garantia referem-se a informações obtidas de especialistas, já que dados após a garantia apresentam elevado nível de censura. Equações de confiabilidade e estimadores de máxima verossimilhança são apresentados para definir o perfil e os parâmetros do modelo proposto. Um estudo de caso com dados coletados de um equipamento elétrico-eletrônico subsidia a aplicação do modelo enquanto que um teste estatístico de ajuste de dados é utilizado para validar o referido modelo. / This thesis presents a reliability model for product life data presenting three different failure modes, associated with early, random and wear-out failures. The model is based on theoretical concepts related to competing risk and sectional models. The proposed model is structured based on two Weibull distributions, with two and three parameters, and one exponential distribution. The Weibull distribution with two parameters is aimed at modeling early failure modes; the Weibull distribution with three parameters models wear-out failure modes; the exponential distribution models random failures due to operational use. It is considered that early and wearout failures take place one after the other while random failures occur at the same time as early and wear-out failures as soon as the product starts operating. To measure each period related to the three failure modes, data from warranty and post-warranty periods are used. Warranty data are historical records; post-warranty data are gathered from experts, and are aimed at decreasing the degree of censoring in the data. Once the model is defined, reliability figures and maximum likelihood estimators are derived. Real data obtained from warranty claims on electricelectronic equipments are used to illustrate the developments proposed and a goodness-of-fit test is used to validate the performance of this model.

Submitted by Elielson Nobrega da Silva (nobrega_elielson@hotmail.com) on 2018-11-09T01:23:55Z No. of bitstreams: 1 Dissertação Ficha 08_11_1.pdf: 3453656 bytes, checksum: a1cff4951db4dde58ae977a59c6423b6 (MD5) / Approved for entry into archive by Silvana Alvarez null (silvana@ict.unesp.br) on 2018-11-19T18:56:22Z (GMT) No. of bitstreams: 1 silva_en_me_sjc.pdf: 3453656 bytes, checksum: a1cff4951db4dde58ae977a59c6423b6 (MD5) / Made available in DSpace on 2018-11-19T18:56:22Z (GMT). No. of bitstreams: 1 silva_en_me_sjc.pdf: 3453656 bytes, checksum: a1cff4951db4dde58ae977a59c6423b6 (MD5) Previous issue date: 2018-08-21 / A introdução da zircônia na Odontologia deu-se pela necessidade de melhores propriedades mecânicas dos materiais cerâmicos, pois com a crescente demanda estética, os cerâmicos tornaram-se materiais de largo uso, devido às suas propriedades estéticas e mecânicas. Em busca dessas propriedades, vários estudos analisaram a taxa de sobrevivência de restaurações zircônia-porcelana, relatando como uma das causas de falha a fratura precoce da porcelana de cobertura e o aumento significativo nos relatos clínicos de lascamento da porcelana de recobrimento aplicada sobre "coping" de zircônia. Diante desse problema, o objetivo deste trabalho foi determinar a tensão de falha no lascamento a partir de casos de clínicos e experimentais pertinentes a esse fenômeno em próteses fixas livres de metal .Foram coletados dados de artigos dos últimos 15 anos, por meio das bases de dados Pubmed e Google Schoolar, sendo selecionados para essa revisão os que obtiveram melhor abordagem do assunto, dando ênfase às possíveis causas de falhas nas restaurações cerâmicas dos casos clínicos e os ensaios realizados, visando um melhor entendimento desse fenômeno, via análise quantitativa e qualitativa, para melhor utilização e aproveitamento desse material na Odontologia. Para determinação da tensão de falha, foi empregada a mecânica da fratura linear elástica e determinado o fator de correção da trinca com base nas dimensões da trinca.Com a presente pesquisa, nota-se que amplitude de tensão influencia no processo de fratura, embora não tenha apontado exatamente para a causa da fratura. No entanto, pode-se inferir que uma baixa taxa de sobrevivência está relacionada a um grande defeito que, por sua vez, necessitou de uma sobrecarga para conduzir o processo de lascamento. Portanto, melhorias no processo de fabricação podem otimizar as características do material e sua aplicação final para suportar as tensões, a fim de aumentar a taxa de sobrevivência. / The introduction of zirconia in dentistry was due to the need for better mechanical properties of ceramic materials, because of an increasing aesthetic demand. Ceramics became widely used materials due to their aesthetic and mechanical properties. Aiming at these properties, several studies have analyzed the survival rate of zirconia-porcelain restorations, reporting as one of the causes of failure. Early porcelain fracture coverage and a significant increase in clinical reports of veneering porcelain applied over "coping "of zirconia. In view of this problem, the objective of this work was to determine the failure causes of chipping from clinical and experimental cases associated to this phenomenon in fixed metal free prostheses. Data from articles of the last 15 years were collected through the Pubmed and Google Schoolar databases. Those who obtained the best approach to the subject were selected for this analysis, emphasizing the possible causes of failures in the ceramic restorations of the clinical cases and the tests performed. Aiming for a better understanding of this phenomenon, via quantitative and qualitative analysis, to better use this material in dentistry. To determine the failure causes, linear elastic fracture mechanics were used and the crack correction factor was determined based on the crack dimensions. With the present research, it is noticed that stress amplitude influences in the fracture process, although it has not pointed exactly the cause of the fracture. However, it can be inferred that a low survival rate is related to a large defect, this in turn needed an overload to conduct the chipping process. Therefore, the manufacturing process can improve the characteristics of the material and its final application to withstand the stresses in order to increase the survival rate.