Integrally heated composite tooling (IHCT) is seen as a low cost alternative to autoclave manufacturing of polymer matrix composites (PMCs). IHCTs consist of a composite tool heated by surface heaters; temperature distribution is ensured by a thermally conductive metallic layer. The main original contributions of this thesis was the development of a new method for applying copper coatings onto carbon fibre/epoxy PMCs using pulsed gas dynamic spraying, the production of larger size samples, and the characterisation of the performance of the coatings and laminates obtained. It was shown that this method has potential for producing the thermally conductive layer in an IHCT. Another contribution was the characterisation of parameters affecting temperature distribution across IHCTs through heat transfer simulations, leading to guidelines for IHCT design.

Integrally heated composite tooling (IHCT) is seen as a low cost alternative to autoclave manufacturing of polymer matrix composites (PMCs). IHCTs consist of a composite tool heated by surface heaters; temperature distribution is ensured by a thermally conductive metallic layer. The main original contributions of this thesis was the development of a new method for applying copper coatings onto carbon fibre/epoxy PMCs using pulsed gas dynamic spraying, the production of larger size samples, and the characterisation of the performance of the coatings and laminates obtained. It was shown that this method has potential for producing the thermally conductive layer in an IHCT. Another contribution was the characterisation of parameters affecting temperature distribution across IHCTs through heat transfer simulations, leading to guidelines for IHCT design.

This study is concerned with the development and implementation of a preconditioner for a set of hyperbolic partial differential equations resulting from a new 5-moment closure for the prediction of gas flows both in and out of local equilibrium. This new 5-moment closure offers a robust and efficient system of first-order hyperbolic partial differential equations that has proven to provide an accurate treatment of one-dimensional gases, both in and for significant departures from local thermodynamic equilibrium. However, numerical computations using this model have proven to be difficult as a result of a singularity in the closing flux of the system. This also causes infinitely large wavespeeds in the system. The main goal of this work is to mitigate these numerical issues. Since the solution of a hyperbolic system is characterized by the waves of the system, one could suggest to scale these wavespeeds to remove the arbitrarily large speeds without altering the solution of the system. To accomplish this, this work starts with a detailed study of the behaviour of the system’s wavespeeds, given by the eigenvalues of the flux Jacobian of the system. Since, it is not possible to solve for these eigenvalues explicitly, it is suggested to approximate them by interpolation between the few states at which these waves can be solved for explicitly. With an estimate for the wavespeeds, the nature of the singularity in the system can be analyzed mathematically. The results of this mathematical analysis are used to develop a preconditioner matrix to remove the singularity from the model. To implement the proposed preconditioned model numerically, a centred-difference scheme with artificial dissipation is proposed. A dual-time-stepping strategy is developed and implemented with implicit Euler time marching for both physical and pseudo time iteration. This dual-time treatment allows the preconditioned system to remain applicable to time-accurate problems and is found to greatly increase the robustness of the solution of the steady-state problems. Solutions to several canonical problems for both continuum and non-equilibrium flow are computed and comparisons are made to classical models.

Successful deposition of thick copper coatings on low carbon steel is a challenge for the Cold Gas Dynamic Spray (CGDS) process if one is to avoid the use of helium as the process gas for the initial pre-coat layer. The issue stems from the presence of accumulated residual stresses, which causes delamination of the weakly bonded coating. Even after exploring different deposition parameters, several copper powders and various steel substrate preparations, copper coating delamination still occurs. The purpose of the current study is to produce copper coatings using only nitrogen as the process gas, while avoiding delamination of the deposited material. To this end, the current work focuses on the study of the effect of steel substrate temperature on particle deposition and adhesion processes. Steel substrates were heated to temperatures between 25°C and 600°C using induction heating and laser. Once the substrate reached the desired temperature, three different copper particle sizes were deposited using the CGDS process. Individual particle impact tests (wipe-tests) were performed to characterize bonded particles and craters from rebounded particles. Further analysis was performed by extracting particles from the surface to understand the effect of substrate temperature and particle size on the particle/substrate deformation and bonding processes. Mechanical adhesion prediction modeling at substrate preheated was also performed to obtain a greater understanding of the bonding mechanism. This prediction is in order to compare with the coating developed with a bond layer coating with helium as process gas and then build the rest of the coating with nitrogen. The experimental results show a significant trend as the substrate temperature increases, indicating proper conditions for enhanced adhesion.

A novel torsion pendulum thrust test stand for micro-Newton-scale spacecraft thrusters is described. The stand is designed to be robust against electromagnetic interference effects internal or external to the thruster being tested. The design and testing of a gas-dynamic calibration thruster is included. This thruster is fully self-contained on the pendulum arm, with no external wires or feedlines connected to the device and impacting the dynamic response of the underlying pendulum. Initial calibration results are shown. Zero drift and hysteresis are present in the results, evidenced by a constant steady-state displacement drift and a return to a different displacement after shutdown of the calibration thruster. Results are compared to theoretical solutions of the equation of motion. An external forcing function of facility effects is described for discrepancies between results and the theoretical solution. Further work to eliminate these effects and add damping are proposed. / MS / Many recently proposed space missions require very fine vehicle attitude and position control in support of their science objectives. Thrusters with the ability to provide this control are currently in development, from laboratory proofs of concept to initial test flights on pathfinding missions. The low levels of thrust produced by these devices, in the range of less than the weight of a mosquito, require specialized test stands with very fine resolution. This thesis describes a novel torsion pendulum design for measuring these thrusters as well as initial validation results from its calibration system using rarefied gas flow. This calibration device is fully-contained on the device’s arm, removing many common sources of compensation factors which are often needed for other test stand designs. A custom-built displacement measuring system for determining angular motion of the pendulum arm is described which allows for measuring angular displacements of the arm to the level of arcseconds and potentially fractions thereof. Initial results suggest measurement of the expected levels of thrust, while some work remains to remove lingering sources of error and achieve more precise thrust data.

The objective of this study is to successfully deposit Titanium Ti-6Al-4V layers onto Ti-6Al-4V substrate using two new commercially available Cold Spray processes such as Low Pressure Cold Spray (LPCS) and Pulsed Gas Dynamic Spray (PGDS). The second objective of this work is to develop a technique to repair Titanium parts since there is currently no repair technique commercially available. It is envisioned that commercial cold spray systems could be used to repair gashes on Titanium components. The examination of both feedstock powders and coatings were performed by different techniques such as optical microscopy and Scanning Electron Microscopy (SEM). Porosity, hardness, adhesion strength, flattening ratio, wipe test, fracture surface, wear test, XRD and chemical composition of the coatings using EDS have been evaluated. Cold spray has shown to be a promising technique for the deposition of heat sensitive particles such as titanium. LPCS and PGDS both produced high quality coatings. Low porosity, high hardness, adhesion strength over 40 MPa, metallurgical bonding, similar to bulk material wear rate, no oxide and nitride phases inside coating were measured.

The cold gas dynamic spray process developed in the middle of the 80’s reached the industrial stage in development. Even so, many scientific investigations still go on. The nature of the bond between the coating and the substrate is the subject of some controversy. The development of the process will be improved by understanding how the properties of the powder and the mechanical properties of the substrate influence the bonding process. This study analyses the basic dynamics of the process when copper is sprayed. • The one dimensional isentropic model of the gas behaviour in a Laval type nozzle allows evaluating the effect of the gas stagnation pressure P0 and temperature T0 on the impact velocity and temperature of the powder particle. • The analysis of single splats on two substrates (aluminium and steel) shows the influence of the substrate on the deformation of single particles and the influence of the impact speed on the impact shape. • Coatings are made of with powders with a specific size distribution. Two copper powders with a different size distribution are compared based on the deposition efficiency (D.E.) and the mechanical properties of the coating. The mechanical properties tested are the microhardness, the bond strength and the nanohardness. • X-ray diffraction will show that the two powders have an initial very different microstructure. The consequence of this is a different deformation mechanism during the coating build up. • An Auger analysis of the interface has shown the presence of diffusion zone when copper was sprayed on the Al and TA6V substrate. It appears that the size distribution will determine the final impact conditions of the powder. The microstructure of the powder and the oxide content of the powder yield different deformation processes and may explain the differences in D.E. and mechanical properties. The Auger analysis of the interface has yielded diffusion zone that were not expected but some mechanisms under impact loading can explain their presence./ Le procédé de projection thermique à froid a été développé dans le milieu des années 80 et il arrive au stade industriel. Néanmoins, plusieurs développements scientifiques sont encore en cours. La nature du lien entre la poudre et le substrat est toujours l’objet de certaines controverses. Le développement futur du procédé nécessite une bonne compréhension de l’influence de la poudre et des propriétés du substrat sur le mécanisme d’adhérence. Cette étude va mettre en évidence les principaux facteurs influençant la projection de cuivre. • Le modèle unidimensionnel isentropique du gaz parfait dans une buse convergente/ divergente permet de déterminer l’influence de la pression de stagnation et de la température de stagnation sur la vitesse et la température d’impact des particules de poudre. • L’analyse d’impact unique sur les substrats d’acier et d’alliage d’Al (AA2014) montre l’influence du substrat sur la déformation des particules de poudre. La vitesse d’impact a une conséquence importante sur la forme d’une particule projetée sur une surface. . • Les revêtements sont fabriqués à partir de poudre avec une granulométrie donnée. Deux poudres avec une distribution de taille différente sont comparées par leur rendement de déposition et les propriétés mécaniques des revêtements obtenus. Les propriétés mécaniques testées sont la microdureté, l’adhérence et la nanodureté. • La diffraction par rayons-X montre que les deux poudres ont initialement une microstructure très différente. Lors de l’impact, les deux poudres vont se déformer de manière différente et ceci se traduit dans la microstructure. • La spectroscopie Auger montre qu’une zone de diffusion s’est formée à l’interface entre le cuivre et les deux substrats d’Al et de TA6V. La distribution de taille des poudres a une influence considérable sur la vitesse et la température d’impact des particules de poudres mais il apparaît que d’autres facteurs ont aussi énormément d’influence. Le taux d’oxyde dans la poudre a une influence très importante sur le rendement et l’adhérence du dépôt. Les deux poudres projetées ont une microstructure initiale très différente et ceci se traduit par une déformation différente des particules de poudre dans le revêtement.

The majority of the structural weight of many common commercial aircrafts is composed of high strength aluminum alloys. The properties of high performance aluminum alloys such as a high strength to weight ratio (specific strength), ease of recycling, crash energy absorption capacity, and corrosion resistance make them ideal for use in the aerospace field. As a result of the high performance nature of the parts and specific properties of the materials, manufacturing requires intricate casting, precision machining, and specific heat treatments – which results in expensive components. As a result of its excellent corrosion resistance properties, pure aluminum coatings are commonly used in the aerospace field for corrosion protection of steel, aluminum alloy components, and titanium alloy components. The common method to deposit these coatings is called ion vapour deposition (IVD). These IVD aluminum coatings provide the coating adhesion, coverage, thickness, and corrosion resistance required to protect the part. The present study was motivated by the potential use of the cold gas dynamic spray (CGDS) process to repair a) damaged aluminum alloy aerospace parts and b) damaged pure aluminum IVD coatings. The primary research objective was to successfully produce these repairs using commercially available aluminum alloy feedstock powders deposited with commercially available CGDS equipment. This work was treated as prequalification work for The Boeing Company to commercialize this process and therefore the repairs aim to meet the same standards (military and industrial) required of the original aluminum alloy parts and IVD aluminum coatings. The use of CGDS was shown in this research to be a very promising as a process for the restoration of aluminum alloy aerospace components. The adhesion strength of the repaired aluminum components was found to be well above the accepted range for thermally sprayed repairs according to industrial standards. The repairs were subjected to a highly corrosive environment and showed only minor pitting. These sites could be reduced in the future with improved machining techniques and attention to surface detail prior to exposure to the salt fog. The only requirement that the repaired components did not meet was for the wear properties of the anodized layer, measured thought Taber abrasion testing. The results of this test, at times, approached the desired values, and it is believed that, in the future, the quality and consistency of the coatings could be improved and the test would meet industrial standards. The results of this research show that the use of CGDS as a process for the restoration of damaged aluminum IVD coatings is possible and is a promising alternative to conventional methods. The CGDS coatings were scrutinized to the same level as required of IVD coatings when they replaced toxic cadmium coatings in the late 1980s. The coating adhesion, demonstrated through glass bead abrasion and strip rupture testing, was shown to meet the current industrial standards. The corrosion testing of the repairs resulted in no visible red rust of the steel components, even when the steel was exposed.

Within the framework of an Institutional Partnership of the Alexander von Humboldt Foundation, the Budker Institute of Nuclear Physics Novisibirsk (BINP) and Forschungszentrum Dresden-Rossendorf worked together in a joint project devoted to the research at the coupled GDT-SHIP facility of the BINP with the focus on the study of plasma phenomena within the SHIP mirror section. The project began at July 1st, 2005 and ended on August 30th, 2008. It included work packages of significant theoretical, computational and analyzing investigations. The focus of this final report is on the presentation of results achieved whereas the work that was done is described briefly only. Chapter 2 illustrates the GDT-SHIP facility and describes shortly the planned topics of the SHIP plasma research. Chapter 3 explains the main extensions and modifications of the Integrated Transport Code System (ITCS) which were necessary for the calculations of the fast ion and neutral gas particle fields in SHIP, describes briefly the scheme of computations and presents significant results of pre-calculations from which conclusions were drawn regarding the experimental program of SHIP. In chapter 4, the theoretical and computational investigations of self-organizing processes in two-component plasmas of the GDT-SHIP device are explained and the results hitherto achieved are presented. In chapter 5, significant results of several experiments with moderate and with enhanced plasma parameters are presented and compared with computational results obtained with the ITCS. Preparing neutron measurements which are planned for neutron producing experiments with deuterium injection, Monte Carlo neutron transport calculations with the MCNP code were also carried out. The results are presented. Finally, from the results obtained within the joint research project important conclusions are drawn in chapter 6.

The objective of this study is to investigate the feasibility of depositing 1.5 mm thick titanium coatings, as a repair method for aerospace Ti-6Al-4V substrates, using two new commercially available processes: Low Pressure Cold Spray (LPCS) and Pulsed Gas Dynamic Spray (PGDS). The coatings produced were examined and characterized by their porosity level, microhardness, adhesion strength, particle flattening ratio, wipe tests, fracture surface type and wear tests. Phases and chemical composition were determined using X-Ray diffraction analysis and energy dispersive spectroscopy, respectively. It was found that both spraying processes are capable of producing dense, hard and oxide-free coatings using specific parameters. Finally, as a first step towards repair implementation of these processes, damages were simulated on Ti-6Al-4V samples, which were successfully repaired with low porosity and high hardness levels. The feasibility of repairs was confirmed, the next step will consist in qualification testing to assess coating performances under real life application.