Friction stir spot welding (FSSW) is a solid-state welding process which is especially useful for joining precipitation-hardened aluminium alloys that undergo adverse property changes during fusion welding. It also has potential as an effective method for solid-state joining of dissimilar alloys. In FSSW, heat generation and plastic flow are strongly linked, and the scale of the process in time and space is such that it is difficult to separate and control the influence of all the relevant input parameters. The use of modelling is well-established in the field of welding research, and this thesis presents an analysis of the thermal and mechanical aspects of FSSW, principally using the finite element (FE) technique. Firstly, a thermal FE model is shown, which is subsequently validated by reference to experimental temperature data in both aluminium-to-aluminium and aluminium-to-steel welds. Correlations between high-quality welds and temperature fields are established, and predictions are made for peak temperatures reached under novel welding conditions. Deformation and heating are strongly linked in FSSW, but existing modelling tools are poorly suited to modelling flow processes in the conditions extant in FSSW. This thesis discusses the development and optimisation of two novel techniques to overcome the limitations of current approaches. The first of these uses greatly simplified constitutive behaviour to convert the problem into one defined purely by kinematics. In doing so, the boundary conditions reduce to a small number of assumptions about the contact conditions between weld material and tool, and the model calculation time is very rapid. This model is used to investigate changes in the slip condition at the tool to workpiece interface without an explicit statement of the friction law. Marker experiments are presented which use dissimilar composition but similar strength alloys to visualise flow patterns. The layering behaviour and surface patterns observed in the model agree well with observations from these experiments. The second approach extends the FE method to include deformation behaviour without the need for a fully-coupled approach, guided by the kinematic model. This is achieved using an innovative sequential small-strain analysis method in which thermal and deformation analyses alternate, with each running at a very different timescale. This technique avoids the requirement to either remesh the model domain at high strains or to use an explicit integration scheme, both of which impose penalties in calculation time and model complexity. The method is used to relate the purely thermal analysis developed in the work on thermal modelling to welding parameters such as tool speed. The model enables predictions of the spatial and temporal evolution of heat generation to be made directly from the constitutive behaviour of the alloy and the assumed velocity profile at the tool-workpiece interface. Predictions of the resulting temperature history are matched to experimental data and novel conditions are simulated, and these predictions correlate accurately with experimental results. Hence, the model is used to predict welding outcomes for situations for which no experimental data exists, and process charts are produced to describe optimum welding parameters. The methods and results presented in this thesis have significant implications for modelling friction stir spot welding, from optimising process conditions, to integration with microstructural models (to predict softening in the heat-affected zone, or the formation of intermetallics at the interface in dissimilar welds). The technique developed for sequential small strain finite element analysis could also be investigated for use in other kinematically constrained solid-state friction joining processes.

No description available.

Puncture resistance is among the major mechanical properties often required for protective clothing, especially in the medical sector. However the intrinsic material parameters controlling puncture resistance of protective materials are still unknown. Therefore, the purpose of this work is to study the mechanism and mechanical behaviors of puncture resistance of protective clothing materials to various probe types. A better understanding of puncture mechanics will be helpful to develop suitable methods to evaluate the puncture resistance and to predict the failure of protective clothing materials. The thesis includes 4 articles which expose two major phases in this study. Article I and II studied the mechanics and mechanisms of puncture by conical and cylindrical probes used in the standard test methods (ASTM F1342 and ISO 13996). The results show that the punctures of rubber membranes by conical and cylindrical probes are controlled by a maximum local deformation (or puncture failure strain) that is independent of the probe geometry. The puncture strengths of elastomer membranes are much lower than their tensile and biaxial strengths. In addition, a simpler cylindrical probe can be used in the place of the costly conical probe required by the ASTM standard and still provides a quantitative characterization of puncture. Actually, since 2005, an alternative method B had been added to F1342 ASTM with 0.5 mm-diameter rounded-tip cylindrical probe. Furthermore, the puncture probes used in the ASTM F1342 are very different to the actual pointed objects (medical needle, pointed tip of knife... ) and cannot accurately characterize the puncture resistance to real objects. Therefore, in the second step, the mechanics and mechanisms of puncture by medical needles were studied. Article III shows that the puncture by sharp-pointed objects like medical needles is very different from the puncture by conical probes used in the ASTM standard test. For medical needles, the puncture resistance involves cutting and fracture energy of material. Using the fracture mechanics, based on the change in strain energy with the change in fracture surface, the fracture energy in puncture was estimated. This calculation assumes that there is no friction between the needle tip and fracture surface. However, even with the application of a lubricant on the needle surface, the effect of friction on the puncture process cannot be totally eliminated, preventing the determination of the material fracture energy. Therefore, Article IV has described a method, similar to that of Lake and Yeoh for cutting to access the precise value of fracture energy in puncture of rubbers by sharp-pointed objects. The method allows substantially eliminating the effects of friction on the evaluation of the fracture energy involved in the puncture process.

Axial piston pumps and motors are widely used in heavy-duty applications and play a fundamental role in hydrostatic and power split drives. The mechanical power losses in hydraulic piston pumps come from the friction between parts in relative motion. The improvement, albeit marginal, in overall efficiency of these components may significantly impact the global efficiency of the machine. The friction between slipper and swash plate is a functional key in an axial piston pump, especially when the pump (at low rotational speed or at partial displacement) works in the critical areas where the efficiency is low. The application of special surface treatments have been exploited in pioneering works in the past, trying different surface finishing or adding ceramic or heterogeneous metallic layers. The potential of structured coatings at nanoscale, with superhydrophobic and oleophobic characteristics, has never been exploited. Due to the difficulty to reproduce the real working conditions of axial piston pump slippers, it has been made a hydraulic test bench properly designed in order to compare the performance of nano-coated slippers with respect to standard ones. The nano-coated and standard slippers have been subjected to the following working conditions: a test at variable pressure and constant rotational speed, a test at constant pressure and variable rotational speed. The comparison between standard and nanocoated slippers, for both working conditions, shows clearly that more than 20% of friction reduction can be achieved using the proposed nano-coating methodology.

Silicon-based nanostructures are essential building blocks for nanoelectronic devices and nano-electromechanical systems (NEMS). As the silicon device size continues to scale down, the surface to volume ratio becomes larger, rendering the properties of surfaces and interfaces more important for improving the properties of the nano-devices and systems. One of those properties is the friction, which is important in controlling the functionality and reliability of the nano-device and systems. The goal of this dissertation is to investigate the deformation and friction behaviors of single crystalline silicon nanolines (SiNLs) using nanoindentation techniques. Following an introduction and a summary of the theoretical background of contact friction in Chapters 1 and 2, the results of this thesis are presented in three chapters. In Chapter 3, the fabrication of the silicon nanolines is described. The fabrication method yielded high-quality single-crystals with line width ranging from 30nm to 90nm and height to width aspect ratio ranging from 10 to 25. These SiNL structures have properties and dimensions well suited for the study of the mechanical and friction behaviors at the nanoscale. In Chapter 4, we describe the study of the mechanical properties of SiNLs using the nanoindentation method. The loading-displacement curves show that the critical load to induce the buckling of the SiNLs can be correlated to the contact friction and geometry of SiNLs. A map was built as a guideline to describe the selection of buckling modes. The map was divided into three regions where different regions correlate to different buckling modes including Mode I, Mode II and slidingbending of SiNLs. In Chapter 5, we describe the study of the contact friction of the SiNL structures. The friction coefficient at the contact was extracted from the loaddisplacement curves. Subsequently, the frictional shear stress was evaluated. In addition, the effect of the interface between the indenter and SiNLs was investigated using SiNLs with surfaces coated by a thin silicon dioxide or chromium film. The material of the interface was found to influence significantly the contact friction and its behavior. Cyclic loading-unloading experiments showed the friction coefficient dramatically changed after only a few loading cycles, indicating the contact history is important in controlling the friction behaviors of SiNLs at nanoscales. This thesis is concluded with a summary of the results and proposed future studies. / text

As the fluidic devices are miniaturized to improve portability, the friction of the microchannel becomes intrinsically high and a high pumping power will be required to drive the fluid. Since the pumping power delivered by portable devices is limited, one method to reduce this is to render the surface to become slippery. This can be achieved by roughening up the microchannel wall and form a bed of air pockets between the roughness elements, which is known as the superhydrophobic Cassie-Baxter state. While the study on superhydrophobic microchannels are focused mainly in maximizing the friction reduction effects and maintaining the stability of the air pockets, less attention has been given to characterizing the microchannel friction under a metastable state, where partial flooding of the micro-textures may be present, and under heated conditions, where the air pockets are trapped between the micro-textures. In order to quantify the frictional characteristics, microchannels with micron-sized trenches on the side walls were fabricated and tested under varying inlet pressures and heating conditions. By measuring the hydrodynamic resistance and comparing with numerical simulations, results suggest that (1) the air-water interface behaves close to a no-slip boundary condition, (2) friction becomes insensitive to the wetting degree once the micro-trenches become highly wetting, (3) the fully wetted micro-trench may be beneficial over the de-wetted ones in order to achieve friction reduction effects and (4) heating the micro-trenches to induce a highly de-wetting state may actually be detrimental to the microchannel flow due the excessive growth of the air layer. As part of the future work to characterize heat transfer in superhydrophobic microchannels, a rectangular microchannel with microheaters embedded close to the side walls was fabricated and the corresponding heat transfer rates were measured through dual fluorescence thermometry. Results suggested that significant heat is lost through the environment despite the high thermal resistance of the microchannel material. An extra insulation is suggested prior to characterizing the convective heat transfer coefficients in the superhydrophobic microchannel flow. / text

No description available.

New computer technologies are applied to the classical material engineering two-body abrasive wear process. The computer simulation provides an interactive and visual representation of the wear process. The influence of grit size, grit tip radius and load (at constant workpiece hardness and tool path) on the wear rate, wear coefficient and wear surface topography is predicted. The simulation implements microcutting and microploughing with material displacement to the sides of the groove. The validation of the simulation is demonstrated by comparing with the previous modelling literature and with experiments. / Thesis (M.Sc.)-University of Natal,Durban, 2002.

The general trend in gear industry is an increased focus on gear transmission efficiency. This thesis focuses on the understanding of how different gear manufacturing methods – particularly the contribution of the running-in process – affect the surface characteristics and friction response, with the purpose of increasing gearbox efficiency. The thesis consists of a summary and five appended papers. The research hypothesis in paper A and paper B was that the dry elastic contact area ratio is a descriptive parameter for the contact condition. Paper A deals with the influence of manufacturing method on the initial contact conditions. The emphasis in paper B is the changes that occur during running-in and correlating these changes to design requirements. Paper C examines the influence of manganese phosphate coating and lubricants, with respect to friction and the risk of scuffing at the initial contact. Paper D examines the effect of running-in load on the friction response for different surfaces. In paper E, the question of whether the load during running-in influences the gear mesh efficiency is further expounded. The main conclusions of this thesis are that the running-in influences the gear mesh efficiency; a high running-in load enhances the gear mesh efficiency. The difference in mesh efficiency is in the range of one tenth of a per cent. Thus, the influence of running-in cannot be neglected because it is in the same order of magnitude as reported for other gear efficiency enhancements. Furthermore, the dry elastic contact area ratio presents a descriptive measure of how surface topography influences the contact, at both a global (form deviation) and local (roughness) level. The surface topography caused by the manufacturing method has a significant influence on the contact area ratio. Shaving was found to have the highest contact area ratio, and would therefore be the best choice if deviations from case hardening could be minimised. It was also confirmed that surfaces coated with manganese phosphate raise the limiting load for scuffing failure up to 13 times compared to the uncoated ground equivalent. / <p>QC 20141002</p>

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