Thesis (M.S. in Operations Research)--Naval Postgraduate School, June 2009. / Thesis Advisor(s): Miller, Nita Lewis. "June 2009." Description based on title screen as viewed on July 10, 2009. Author(s) subject terms: Large truck crash, long-haul truck drivers, heavy truck operations, Large Truck Crash Causation Study, effects of fatigue on driver performance, long-haul operations, commercial transportation carriers, Federal Motor Carrier Safety Administration, National Highway Traffic Safety Administration. Includes bibliographical references (p. 35-37). Also available in print.

Asphalt oxidation causes major changes to binder properties and is hypothesized to be a major contributor to age-related pavement failure such as fatigue cracking. Extensive laboratory aging research has been done to assess the effects of oxidation on binder properties. Previous work shows binder oxidation makes the binder stiffer and more brittle, leading to higher binder stresses under a given deformation. Failure occurs when these stresses exceed the strength of the binder. However, binder oxidation in pavements has not been studied in the same detail as laboratory aging of neat binders. The impact of binder oxidation on long-term pavement performance has been either underestimated or ignored. This research includes studies of binder oxidation in Texas pavements to compare the field aging with laboratory neat binder aging, the impact of binder oxidation on HMAC mixture aging and HMAC mixture fatigue performance, and fundamental rheological property changes of the binder and the mixture. Binder oxidation is studied in fifteen pavements from locations across Texas. Results indicate that unmodified binders in pavements typically oxidize and harden to a degree that exceeds generally accepted pavement aging assumptions. This hardening may also extend much deeper into the pavement than has been previously assumed or documented. Data suggest that pavements can oxidize at rates surprisingly uniform with depth once early oxidation occurs, and that these rates continue for an extended time. Laboratory-aged HMAC mixtures and binders were tested and analyzed for fatigue resistance and their rheological properties. Mixture aging shows the same aging mechanisms as neat binder aging. Both binder and mixture have a higher modulus with aging and a good rheological correlation. The decline in mixture fatigue life (determined using the calibrated mechanistic fatigue analysis approach with surface energy measurement) due to oxidation is significant. Pavement service life is dependent on the mixture, but can be estimated by a cumulative damage approach that considers binder oxidation and pavement loading rate simultaneously. The differences in expected pavement life arise from differences in the rate of binder stiffening due to oxidation and the impact of this stiffening on the decline of fatigue life.

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This thesis investigates the behaviour of UHPC as a fill material for precast deck panels subjected to negative bending. Two full-scale test specimens were constructed. The transverse joints between the panels, the shear pockets, and the deck haunches were all filled with UHPC. A total of four tests were performed including two static tests to failure and two fatigue tests, one of which was performed to failure. Testing consisted of a loading apparatus acting upwards on the deck soffit in an attempt to impose tensile stresses across the transverse joints, representing the conditions that a transverse joint in the negative moment region of a continuous bridge deck would experience. It was concluded that the transverse UHPC joint performed satisfactorily by transferring bending stresses and shear stresses across the joint from one panel to the adjacent panel. Overall, the test specimens displayed performance levels expected from conventional cast-in-place concrete deck alternatives. / February 2016

Master of Science / Civil Engineering / Mustaque A. Hossain / Approximately 89% of 11,000 miles of Kansas roads are surfaced with asphalt. Hundreds of thousands of tons of reclaimed asphalt pavement (RAP) are produced annually in the United States, including in Kansas. This bulk volume of RAP must be economically managed in order to achieve environmental friendliness. Recycling of RAP conserves natural resources and reduces landfill usage. However, many agencies have reported that increased RAP content produces drier hot-mix asphalt (HMA) mixtures than virgin mixtures that are susceptible to premature cracking. In this research, laboratory-produced Superpave HMA mixtures containing increased percentages (20, 30, and 40%) of RAP materials from three RAP sources (Shilling Construction Co., Konza Co., and the Kansas Department of Transportation’s project, US 73) were studied for cracking performance. Mix designs were produced using Superpave design criteria for 12.5-mm nominal maximum aggregate size mixture. The static and repetitive Semicircular Bending (SCB) test, the Texas Overlay Tester test, the dynamic modulus test, and Viscoelastic Continuum Damage (VECD) tests were performed on laboratory-prepared samples. In general, cracking performance decreased with increased RAP content. The RAP from the US 73 project performed most consistently compared to other two sources of RAPs. Test results were analyzed using two-way Analysis of Variance (ANOVA), proving that mixtures containing 4.5% to 4.9% binder performed the best against cracking. The RAP source was found to have more effect on cracking propensity than RAP content. Mixtures with RAP content up to 40% performed satisfactorily. Tukey’s pairwise comparison method was used to compare results from all tests; VECD was determined to be the most appropriate test to evaluate cracking propensity of HMA mixtures.

The physical demands of soccer players competing in the English Premier League have significantly increased in recent years (Barnes et al. 2014; Bush et al. 2015). Elite soccer players are required to compete on a weekly and often bi-weekly basis during a 9-month competitive season. During periods of fixture congestion, players may participate in three matches within a 7-day period. Previous researchers have reported that some components of performance and physiological measures may still be below a pre-match baseline 72 hours following match-play (Mohr et al., 2003; Andersson et al., 2008; Ispirlidis et al., 2008; Fatouros et al., 2010). Nevertheless, data are sparse for the quantification of player fatigue status during competitive periods. Therefore, the primary aim of this thesis is to evaluate potential indicators of fatigue which may be easily measured and utilised in elite soccer. The aim of the first study (Chapter 4) was to quantify the test-retest reliability of a range of potential fatigue variables in elite soccer players. During the pre-season period, resting perceived ratings of wellness (fatigue, muscle soreness, sleep quality and stress), counter-movement jump height (CMJ), sub-maximal heart rate (HRex), post-exercise heart rate recovery (HRRbpm and HRR%), heart rate variability (rMSSD and LnrMSSD) and salivary immunoglobulin-A (S-IgA) were measured during the morning on two consecutive non-training days in thirty-five English Premiership players. Mean values of perceived ratings of wellness (7-13 %CV), CMJ (4 %CV) HRex (3 %CV) and HRR% (10 %CV) were not substantially or statistically significantly different between days. HRV measures’ rMSSD (28 %CV) and Ln rMSSD (10 %CV), perceived ratings of sleep (CV 13%CV) and S-IgA (63 %CV) were statistically significantly different between days. All morning-measured fatigue variables with the exception of S-IgA were reliable enough to allow feasible sample sizes in future pre/post studies. These data indicate that the use of perceived ratings of wellness, CMJ, HRR%, and, to a certain extent, HRV (Ln rMSSD) are reliable enough to monitor the fatigue status of a sample of elite soccer players. The aim of the second study (Chapter 5) was to quantify the relationship between daily training load and a range of potential measures of fatigue in elite soccer players during an in-season competitive phase (17-days). Total high-intensity running (THIR) distance, perceived ratings of wellness (fatigue, muscle soreness, sleep quality), CMJ, HRex, HRR% and heart rate variability (Ln rMSSD) were analysed during an in-season competitive period (17 days). Within-subject fluctuations in fatigue (r=-0.51; large; P<0.001), Ln rMSSD (r=-0.24; small; P=0.04), and CMJ (r=0.23; small; P=0.04) were significantly correlated with fluctuations in THIR distance over the study period. Correlations between variability in perceived muscle soreness and sleep quality and HRR% and THIR distance were negligible and not statistically significant. Perceived ratings of fatigue and heart rate variability were sensitive to daily fluctuations in THIR distance in a sample of elite soccer players. Therefore, these specific markers show particular promise as simple, non-invasive assessments of fatigue status in elite soccer players during a short in-season competitive phase. The aim of the third study (Chapter 6) was to determine whether the sensitivity of a range of potential fatigue measures studied in Chapter 5 would be improved compared with the training load accumulated over the previous two, three or four days during a short in-season competitive period (17-days). Fluctuations in fatigue (r=-0.28-0.51; “small” to “large”; p<0.05) were correlated with fluctuations in THIR distance accumulation (1-4-day). Changes in HRex (r=0.28; small; p= 0.02) was correlated with changes in 4-day THIR distance accumulation. Fluctuations in Ln rMSSD (r=-0.24; small; P=0.04), and CMJ (r=0.23; small; P=0.04) were only sensitive to changes in THIR distance for the previous day (Chapter 5). Correlations between variability in muscle soreness, sleep quality and HRR% and THIR distance were negligible and not statistically significant for all accumulation training loads. Perceived ratings of fatigue were sensitive to daily fluctuations in acute THIR distance accumulation although sensitivity attenuated over time. Therefore, the present findings indicate that the sensitivity of morning-measured fatigue measures to changes in training load is not improved when compared with training loads beyond the previous days training. The fourth and final aim of the thesis was to quantify the mean daily changes in training load and parallel changes in measures of fatigue across typical in-season training weeks in elite soccer players. The training load of 29 elite soccer players was measured using the ratings of perceived exertion approach. Perceived ratings of wellness (fatigue, sleep quality and muscle soreness), sub-maximal heart rate (HRex), post-exercise heart rate recovery (HRR) and variability (HRV) were also recorded across training weeks in the in-season competitive period. Morning-measured perceived ratings of fatigue, sleep quality and muscle soreness tracked the changes in RPE-TL, being 35-40% worse on post-match day vs pre-match day (P<0.001). Perceived fatigue, sleep quality and muscle soreness improved by 17-26% from post-match day to three days post-match with further smaller (7-14%) improvements occurring between four days post-match and pre-match day (P<0.01). There were no substantial or statistically significant changes in HRex, HRR% and HRV over the weekly cycle (P>0.05). Morning-measured perceived ratings of fatigue, sleep quality and muscle soreness are clearly more sensitive than HR-derived indices to the daily fluctuations in session load experienced by elite soccer players within a standard in-season week. The results of this thesis have shown that simple, ratings of perceived wellness are reliable and sensitive to short training and competition phases and thus may be a suitable strategy for practitioners to use in the attempt to establish fatigue status in elite soccer players. In particular, this thesis has demonstrated that the greatest sensitivity was observed on a daily basis and during typical training weeks and not during short term load accumulation. . Future work is required to quantify whether perceived ratings of wellness and vagal-related heart rate responses are sensitive to changes in training and match load across an entire competitive season in elite soccer players.

Semi-solid metal (SSM) casting has been widely used in automotive industries to reduce the weight. In RheoMetalTM process which is one of the variations of SSM, the slurry fabrication can be finished within 30 second and can the slurry making process can be integrated into a high pressure die casting (HPDC) route without significant adjustments, making the process a promising alternative for industrial application. However, the application of SSM is still limited due to the semi-solid deformation-induced casting defects, such as macrosegregation and large pores. Due to the short stirring duration, the inefficient stirring is the leading cause of defects formation. Another critical issue in the RheoMetalTM process is the oxidation during the stirring process, which results in the increase of oxides in the castings, reducing the mechanical properties. This study aims to investigate the ductility and the fatigue performance of SSM castings. The main focuses were on the role of the stirring and oxides. The quenched slurry was analyzed to evaluate the effect of the stirring on the particle distribution in the slurry, and its effect on the formation of pores and segregation was discussed. To investigate the oxidation during the slurry making process, two alloys with different Mg content were cast. Scanning electron microscopy (JEOL JSM-7001F SEM) equipped with Energy-dispersive X-ray spectroscopy (EDS) was used to identify the oxides on the fracture surface. Tensile test and fatigue test accompanied with direct current potential drop (DCPD) were performed to investigate the ductility and fatigue performance, respectively. The results suggest that the intensive stirring can avoid the formation of the large clusters, making the particle distribution homogeneous in the slurry. The Mg contents determined the types of the oxides formed in the slurry making process. For alloys with sufficient Mg, the oxides would be MgAl2O4, which exist as small films with numerous cracks, while a large oxides film will be formed in the case of low Mg content. The combined influence of porosity and oxides was concluded. In the 42000 alloy, because of the low Mg content, the ductility was dominated by the large oxide films. In contrast, in the Magsimal 59 alloy, the presence of small oxides (less than 0.2 mm in majority) leads to the influence of oxides on the elongation negligible. However, a good correlation was obtained between the largest pores and ductility. The fatigue test shows that the surface liquid segregation (SLS) determined the fatigue strength under cyclic bend loading, due to its higher hardness. The effect of the inner pores on the fatigue performance was negligible, as the maximum stress was applied on the surface. / Halvsolid metall (SSM) gjutning har använts i stor utsträckning inom bilindustrin för att minska vikten. I RheoMetalTM-processen, som är en av varianterna av SSM, kan slurrytillverkningen avslutas inom 30 sekunder och kan slurryframställningsprocessen integreras i en högtrycksgjutningsrutt (HPDC) utan betydande justeringar, vilket gör processen till ett lovande alternativ för industriell tillämpning. Tillämpningen av SSM är dock fortfarande begränsad på grund av de halvfasta deformationsinducerade gjutdefekterna, såsom makrosegregering och stora porer. På grund av den korta omrörningstiden är den ineffektiva omrörningen den främsta orsaken till att defekter bildas. En annan kritisk fråga i RheoMetalTM-processen är oxidationen under omrörningsprocessen, vilket resulterar i ökningen av oxider i gjutgodset, vilket minskar de mekaniska egenskaperna. Denna studie syftar till att undersöka duktiliteten och utmattningsprestandan hos SSM-gjutgods. Huvudfokus var på omrörningens och oxidernas roll. Den kylda uppslamningen analyserades för att utvärdera effekten av omrörningen på partikelfördelningen i uppslamningen, och dess effekt på bildandet av porer och segregation diskuterades. För att undersöka oxidationen under slurrytillverkningsprocessen göts två legeringar med olika Mg-halt. Svepelektronmikroskopi (JEOL JSM-7001F SEM) utrustad med energidispersiv röntgenspektroskopi (EDS) användes för att identifiera oxiderna på brottytan. Dragtest och utmattningstest tillsammans med likströmspotentialfall (DCPD) utfördes för att undersöka duktiliteten respektive utmattningsprestandan. Resultaten tyder på att den intensiva omrörningen kan undvika bildningen av de stora klustren, vilket gör partikelfördelningen homogen i slammet. Mg-innehållet bestämde vilka typer av oxider som bildades i slurrytillverkningsprocessen. För legeringar med tillräckligt med Mg skulle oxiderna vara MgAl2O4, som finns som små filmer med många sprickor, medan en stor oxidfilm kommer att bildas vid låg Mg-halt. Den kombinerade inverkan av porositet och oxider konstaterades. I 42000-legeringen, på grund av det låga Mg-innehållet, dominerades duktiliteten av de stora oxidfilmerna. Däremot, i Magsimal 59-legeringen, leder närvaron av små oxider (mindre än 0,2 mm i majoritet) till att oxidernas inverkan på förlängningen är försumbar. En god korrelation erhölls dock mellan de största porerna och duktiliteten. Utmattningstestet visar att ytvätskesegregeringen (SLS) bestämde utmattningshållfastheten under cyklisk böjbelastning, på grund av dess högre hårdhet. Effekten av de inre porerna på utmattningsprestandan var försumbar, eftersom den maximala belastningen applicerades på ytan.

This thesis is focused on the analysis and on the design of the milling technology of the components for the aerospace industry which are characterised by a high aspect ratio, reduced stiffness and all covered by a high demand on the fatigue performance. This work includes the experimental verification of the proposed technology using CNC machining center, evaluation of surface structure using optical high-resolution 3D surface measurement system ALICONA, analysis of the force loading using KISTLER device, fatigue testing and fatigue fracture analysis.

For reducing the CO2 footprint in many industrial fields, the goal is to produce lighter components. The aluminium-silicon (Al-Si) cast alloys are promising candidates to fulfill these goals with a high weight-to-strength ratio, good corrosion properties, excellent castability, and recyclable material. However, the variations within these components need to be understood to produce high-performance components for critical applications. The main reason for the rejection in these applications is defects and microstructural features that reduce the mechanical properties. The addition of copper (Cu) is one way of increasing the mechanical properties in Al-Si alloys and is commonly used in the automotive industry. Casting defects harm the mechanical properties, and these defects can be reduced by improving the melt quality, the correct design of the component, and the gating system. The study aims to investigate the static mechanical properties and the crack initiation and propagation under cyclic loading in an Al-7Si-Mg cast alloy with state-of-the-art experiments. The main focuses were on the effect of the HIP process and the role of Cu addition. In-situ cyclic testing using a scanning electron microscope coupled with electron back-scattered diffraction, digital image correlation, focused ion beam (FIB) slicing, and computed tomography scanning was used to evaluate the complex interaction between the crack path and the microstructural features. The amount of Cu retained in the α-Al matrix in as-cast and heat-treated conditions significantly influenced the static mechanical properties by increasing yield strength and ultimate tensile strength with a decrease in elongation. The three-nearest-neighbor distance of eutectic Si and Cu-rich particles and crack tortuosity were new tools to describe the crack propagation in the alloys, showing that a reduced distance between the Cu-rich phases is detrimental for the mechanical properties. Three dimensional tomography using a FIB revealed that the alloy with 3.2 wt.% Cu had a significantly increased quantity of cracked Si particles and intermetallic phases ahead of the crack tip than the Cu-free alloy. The effect of Cu and HIP process in this work shows the complex interaction between the microstructural features and the mechanical properties, and this needs to be considered to produce high-performance components. / Ett sätt att nå målen med minskade koldioxidutsläpp inom industrin är att producera lättare komponenter. Aluminium-kisel (Al-Si) gjutna legeringar är därför ett bra alternativ då dessa legeringar har ett bra förhållande mellan hållfasthet och vikt, goda korrosionsegenskaper, utmärkt gjutbarhet och är ett återvinningsbart material. En av de största utmaningarna för att producera högpresterande komponenter för kritiska applikationer är variationerna i egenskaper inom dessa komponenter. Orsaken till att inte gjutna Al-Si legeringar andvänds i dessa applikationer är förståelsen av defekter och mikrostruktuella faser påverkar de mekaniska egenskaperna negativt. Koppar (Cu) tillsätts i Al-Si legeringar för att öka de mekaniska egenskaperna vilket ofta nyttjas inom bilindustrin. Hot isostatic pressing (HIP) prosessen är en annan möjlighet att förbättra de mekaniska egenskaperna genom att reducera porositeter i materialet. Studien syftar till att undersöka de mekaniska egenskaperna och sprickinitiering och spricktillväxt i en gjuten legering av Al-7Si-Mg med utmattningstestning i svepelektronmikroskop (SEM) i kombination med electron backscatter diffraction, digital image correlation och focused ion beam (FIB). Mängden Cu i Al-Si legeringen påverkade de statiska mekaniska egenskaperna genom att öka sträckgränsen och brottgränsen. Tillsats av Cu upp till 1.5 vikt.% påverkar inte spricktillväxten märkbart. Däremot förändras beteendet markant vid tillsatser av Cu på mer än 3.0 vikt.% som resulterade i en markant reducering i duktilitet. I det värmebehandlade materialet påverkades de mekaniska egenskaperna av Al-matrisen och mängden intermetalliska faser. Avståndet mellan Cu faserna och Si faserna används för att beskriva spricktillväxten i Al-Si legeringarna. Detta tillsammans med tredimensionell tomografi visade att legeringen med 3.2 vikt.% Cu hade en ökad mängd sprickor i området framför den avancerande sprickan, vilket inte den Cu fria legeringen visade. Al-Si legeringen som utsattes för HIP-processen och värmebehandlingen visade att materialets mikrostruktur i gjutet tillstånd påverkade resultatet. HIP processen slöt porositerena i alla undersökta prover och förbättrade de mekaniska egenskaperna. Dessa resultat kommer kunna användas för att konstruera mer högpresterande komponenter.

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