<div>Additively manufactured (AM) metals have been increasingly fabricated for structural applications. However, a major hurdle preventing their extensive application is lack of understanding of their mechanical properties. To address this issue, the objective of this research is to develop a computational model to simulate the creep behavior of nickel alloy 718 manufactured using the laser powder bed fusion (L-PBF) additive manufacturing process. A finite element (FE) model with a subroutine is created for simulating the creep mechanism for 3D printed nickel alloy 718 components.</div><div><br></div><div>A continuum damage mechanics (CDM) approach is employed by implementing a user defined subroutine formulated to accurately capture the creep mechanisms. Using a calibration code, the material constants are determined. The secondary creep and damage constants are derived using the parameter fitting on the experimental data found in literature. The developed FE model is capable to predict the creep deformation, damage evolution, and creep-rupture life. Creep damage and rupture is simulated as defined by the CDM theory.</div><div>The predicted results from the CDM model compare well with experimental data, which are collected from literature for L-PBF manufactured nickel alloy 718 of creep deformation and creep rupture, at different levels of temperature and stress. </div><div><br></div><div>Using the multi-regime Liu-Murakami (L-M) and Kachanov-Rabotnov (K-R) isotropic creep damage formulation, creep deformation and rupture tests of both the secondary and tertiary creep behaviors are modeled.</div><div>A single element FE model is used to validate the model constants. The model shows good agreement with the traditionally wrought manufactured 316 stainless steel and nickel alloy 718 experimental data collected from the literature. Moreover, a full-scale axisymmetric FE model is used to simulate the creep test and the capacity of the model to predict necking, creep damage, and creep-rupture life for L-PBF manufactured nickel alloy 718. The model predictions are then compared to the experimental creep data, with satisfactory agreement.</div><div><br></div><div>In summary, the model developed in this work can reliably predict the creep behavior for 3D printed metals under uniaxial tensile and high temperature conditions.</div>

<p>Controllable continuous feeding of biomass feedstock in a biorefinery is critical to upscaling current ethanol conversion techniques to a commercial scale. Mechanical pretreatment of biomass feedstock performed using a compression feed screw (CFS) improves the ethanol yield but is subject to flowability issues, especially the plugging of biomass. The mechanical behavior, and hence, the flowability of biomass feedstock, is strongly affected by several factors, including preparation method, moisture content, physical composition, and particle size distribution. In addition, the current design of CFS is guided by limited experimentation and even fewer theoretical correlations. This thesis aims at developing computational methods to model the flow of densified feedstock in a CFS and experimental techniques to characterize the mechanical properties required for the model. We adopted a modified Drucker-Prager Cap constitutive (mDPC) law for milled corn stover (a widely used feedstock for bioethanol production) to model the material’s rate-independent bulk behavior in a CFS. The mDPC elastoplastic law captures the frictional shear and permanent volumetric changes in corn stover using a continuous porosity-dependent yield surface. The parameters of the mDPC model are calibrated using a unified set of single-ended die compaction and multiple shear failure tests. In addition, we quantified the changes in the mDPC parameters with moisture content up to the water-holding capacity of corn stover particles. A Coupled Eulerian-Lagrangian Finite Element Method model developed for the CFS geometry predicts the deformation of the material using the calibrated mDPC parameters. We model the interaction between the material and the CFS surface using a Coulomb wall friction coefficient calibrated using the Janssen-Walker method for a punch and die system. A laboratory-scale compression feed screw is designed and fabricated to characterize the flow of dense granular materials in collaboration with undergraduate students in the School of Mechanical Engineering. FEM model predictions of feeding torque and mass flow rate are validated against the laboratory-scale feeder for microcrystalline cellulose Avicel PH-200 and milled corn stover. The model predictions agree with the experiments for Avicel PH-200 but have a higher error in the case of corn stover. Some physical effects, such as shear hardening and particle erosion observed in milled corn stover, are not captured using the current implementation of the mDPC model, which explains the different model accuracies for both materials. The continuum model is used to uncover material density distribution, torque, and pressure inside the CFS, otherwise challenging through experiments. The FEM model showed a significantly higher sensitivity of the feeder performance to two material properties, namely the hydrostatic yield stress and the wall friction coefficient. The characterized variation of material properties with moisture content and the effect of each material property on the feeder performance provide strategies to engineer the feedstock for better flowability. Further, the continuum model offers a method to study design changes before manufacturing the equipment. Finally, we propose the possibility of a reduced-order analytical model based on the critical material properties and the material deformation mechanism demonstrated by the FEM model.</p>

Introduction One out of five reported motor vehicle collision injuries occur to the upper extremities. Certain parts of The Total HUman Model for Safety (THUMS) lack validation against experimental data, including the elbow. The aim of this project is to refine and validate the elbow joint of THUMS, with focus on anatomical response of the elbow during axial impact applied to the wrist. Methods Internal contacts in the elbow were modified and new contacts assigned between bones and ligaments of the elbow. The posterior part of the radial- and ulnar collateral ligaments, and joint capsule was implemented to the model. Elasticmodulus of the cortical bones of the elbow was increased as well as the shell thickness of the humeral cortical bone. The updated model was validated against an experiment where an axial load was applied to the wrist of a female cadaver. The experimental resultant force in the wrist was then compared with the wrist force obtained from the simulations. Results The correlation between the experimental and simulation resultant wrist force for the updated model resulted in a CORA score of 0.882. This gave a 6.7% higher CORA score compared with the original model. Hourglass energy was reduced from 63.52% of internal energy to 0.78%. Energy ratio and contact energies indicated that the simulation was stable. Discussion Movement of elbow bones was assessed to be more anatomically correct, by accounting for the posterior ligament and elbow capsule support. The contact peak force in the humerus was lower and occurred earlier in the simulation in the updated model compared to the original. This is believed to be due to the reduced gap between the elbow bones after increasing the shell thickness of the humeral cortical bone. The model setup resembled the experiment in a good manner. Conclusion The upper extremity of THUMS was refined for improved biofidelity, with focus on the anatomical response of the elbow joint under an axial impact. However, further model improvements are suggested as well as extended validated against other experimental impact results. / Introduktion En av fem rapporterade krockskador med motorfordon förekommer i de övre extremiteterna. Vissa strukturer hos Total HUman Model for Safety (THUMS) saknar validering gentemot experimentell data, där armbågen är ett av dem. Syftet med detta projekt är att förfina och validera armbågsleden hos THUMS, med fokus på dess anatomiska respons under axiellt islag applicerad på handleden. Metod Interna kontakter i armbågen modifierades och nya kontakter tilldelades mellan ben och ligament. De posteriora delarna av kollateral ligament hos radius och ulna implementerades i modellen, så även armbågens ledkapseln. Elasticitetsmodulen hos de kortikala benen i armbågen höjdes och skalets tjocklek idet humerala kortikala benet utökades. Den uppdaterade modellen validerades mot ett experiment där en axiell belastning hade applicerats mot en kvinnlig kadavers handled. Den resulterande kraften i handleden från experimentet jämfördes sedan med erhållen kraft i handleden från simuleringarna. Resultat Korrelationen mellan den experimentella kraften och simulerade kraften hos den uppdaterade modellen resulterade i ett CORA-poäng på 0,882. Detta är en ökning med 6,7% jämfört med den ursprungliga modellen. Hourglassenergin reducerades från 63,52% av inre energi till 0,78%. Energiförhållandet och kontaktenergier indikerade stabil simulering. Diskussion Rörelsen av armbågens ben bedömdes vara mer anatomiskt korrekt, med hänsyn till stödet från de posteriora ligamentet och armbågens ledkapsel. Den maximala islagskraften i humerus minskade och uppträdde tidigare i simuleringen hos den uppdaterade modellen jämfört med originalet. Detta tros bero på reducerat avstånd mellan armbågens ben genom ökandet av skaltjockleken hos det humeralakortikala benet. Modelluppställningen motsvarade experimentets uppställning. Konklusion De övre extremiteterna av THUMS förfinades i syfte att förbättra biofideliteten. Fokus låg på armbågens anatomiska respons under ett axielltislag. Både ytterligare förbättringar av modellen och utökad validering mot andra experimentella islag rekommenderas. / Technology

<p dir="ltr">A current engineering challenge is to understand and validate material systems capable of maintaining structural viability under the elevated temperature and environmental conditions of hypersonic flight. One aspect of this challenge is the joining of multiple materials with thermal expansion mismatch, which can lead to residual stress, resulting in debits in component lifetime under in-service loading. The focus of this work is a series of studies focused on a ceramic-metal composite (WC/Cu), a zirconia coating applied to a carboncarbon (C/C) composite, and a silicide (R512E) coating applied to a Nb-based alloy (C103). Each of these material systems are candidates for elevated temperature applications in which dissimilar constituents result in residual stress in the material. Each study leveraged experimental residual strain measurements, with the primary focus on the use of synchrotron X-ray diffraction, in conjunction with representative models, and microscopy to illuminate the active mechanisms in the development and evolution of residual stress in the bulk material. The combination of experimental and modeling predictions provides a framework to inform the viability and lifing of material systems exhibiting dissimilar expansion properties.</p>