The work presents the research of high-strength cast iron used for manufacturing of large grinding structures with dross layer and with non-homogeneous heat treatment volumes that remains inside during manufacturing process and subjected to high-cycle loading. The original research methodology used for investigations allowed to obtain the results of high-cycle loading. Obtained results have been used to improve the structural elements calculation methods.

The work presents the research of high-strength cast iron used for manufacturing of large grinding structures with dross layer and with non-homogeneous heat treatment volumes that remains inside during manufacturing process and subjected to high-cycle loading. The original research methodology used for investigations allowed to obtain the results of high-cycle loading. Obtained results have been used to improve the structural elements calculation methods.

Sulfide Stress Cracking (SSC) resistance of the newly developed API-X100 High Strength Low Alloy (HSLA) steel was investigated in the NACE TM0177 "A" solution. The NACE TM0177 "A" solution is a hydrogen sulfide (H2S) saturated solution containing 5.0 wt.% sodium chloride (NaC1) and 0.5 wt.% acetic acid (CH3COOH). The aim of this thesis was to study the effect of microstructure, non-metallic inclusions and alloying elements of the X100 on H2S corrosion and SSC susceptibility. The study was conducted by means of electrochemical polarization techniques and constant load (proof ring) testing. Microstructural analysis and electrochemical polarization results for X100were compared with those for X80, an older generation HSLA steel. Uniaxial constant load SSC testing was conducted using X100 samples and the results were compared with those reported for older generation HSLA steels. Addition of H2S to the NACE TM0177 "A" solution increased the corrosion rate of X100from 51.6 to 96.7 mpy. The effect of H2S on the corrosion rate was similar for X80. The corrosion rate for X80 increased from 45.2 to 80.2 mpy when H2S was added to the test solution. Addition of H2S enhanced the anodic kinetics by forming a catalyst (FeHSads) on the metal surface and as a result, shifted the anodic polarization curve to more current densities. Moreover, the cathodic half cell potential increased due to the decrease in pH, from 2.9 to 2.7, which shifted the cathodic polarization curve to more current densities. The increase in both the anodic and cathodic currents, after H2S addition, caused the rise in the corrosion current density. In H2S saturated NACE TM-0177 "A" solution, the X100 steel corrosion rate was higher than the X80 steel by 20%. Longer phase boundaries and larger nonmetallic inclusions in the X100 microstructure generated more areas with dissimilar corrosion potentials and therefore, a stronger driving force for corrosion. Higher density of second phase regions and larger nonmetallic inclusions acted as an increased cathode area on the X100 surface which increased the cathodic current density and consequently, increased the corrosion current density. Proof ring tests on the X100 gave a threshold stress value, C5th, of 46% YS, 343.1 MPa(49.7 ksi). The main failure was caused by SSC cracking. SSC nucleated at corrosion pits on the metal surface and microcracks in the metal body and propagated perpendicular to the applied stress. Hydrogen Induced Cracking (HIC) was observed in the X100. HIC cracks nucleated at banded martensite-ferrite interfaces and propagated along the rolling direction parallel to the applied tensile stress through the softer ferrite phase. When compared to older HSLA grades, the X100 tested in this study had a high SSC susceptibility and therefore, is not be recommended for H2S service applications. The high X100 SSC susceptibility was caused by the material high corrosion rates in H2Smedia which formed corrosion pits that acted as crack initiation sites on the metal surface and provided more hydrogen that migrated into the steel. In addition, the X100 inhomogeneous microstructure provided a high density of hydrogen traps in front of the main crack tip which promoted SSC microcrack formation inside the metal. Microcracks in the metal body connected with the main crack tip that originated from corrosion pits which assisted SSC propagation.

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Ultra-High-Performance Concretes (UHPCs) are a promising class of cementitious materials possessing mechanical properties superior to those of Normal Strength Concretes (NSCs). However, UHPCs have been slow to transition from laboratory testing to insertion in new applications, partly due to an intuitive trial-and-error materials development process. This research seeks to addresses this problem by implementing a materials design process for the design of UHPC materials and structures subject to blast loads with specific impulses between 1.25- and 1.5-MPa-ms and impact loads resulting from the impact of a 0.50-caliber bullet travelling between 900 and 1,000 m/s. The implemented materials design process consists of simultaneous bottom-up deductive mappings and top-down inductive decision paths through a set of process-structure-property-performance (PSPP) relations identified for this purpose. The bottom-up deductive mappings are constructed from a combination of analytical models adopted from the literature and two hierarchical multiscale models developed to simulate the blast performance of a 1,626-mm tall by 864-mm wide UHPC panel and the impact performance of a 305-mm tall by 305-mm wide UHPC panel. Both multiscale models employ models at three length scales – single fiber, multiple fiber, and structural – to quantify deductive relations in terms of fiber pitch (6-36 mm/revolution), fiber volume fraction (0-2%), uniaxial tensile strength of matrix (5-12 MPa), quasi-static tensile strength of fiber-reinforced matrix (10-20 MPa), and dissipated energy density (20-100 kJ/m²). The inductive decision path is formulated within the Inductive Design Exploration Method (IDEM), which determines robust combinations of properties, structures, and processing steps that satisfy the performance requirements. Subsequently, the preferred material and structural designs are determined by rank order of results of objective functions, defined in terms of mass and costs of the UHPC panel.

Nanocrystalline (NC) metals and alloys are known to possess superior mechanical properties, e.g., strength, hardness, and wear-resistance, as compared to conventional microcrystalline materials. NC metals are characterized by a mean grain size <100 nm; in this grain size regime, inelastic deformation can occur via a combination of interface-mediated mechanisms viz., grain boundary sliding/migration, and dislocation nucleation from grain boundary sources. Recent studies have suggested that these interface-mediated inelastic deformation mechanisms in fcc metals are influenced by non-glide stresses and interfacial free volume, unlike dislocation glide mechanisms that operate in microcrystalline fcc metals. Further, observations of tension-compression strength asymmetry in NC metals raise the possibility that yield and inelastic flow in these materials may not be adequately described by solely the deviatoric stress. Unfortunately, most literature concerning the mechanical testing of NC metals is limited to uniaxial deformation or nanoindentation techniques, and the multiaxial deformation behavior is often predicted assuming initially isotropic yield and subsequent flow normal to the yield surface. The primary objective of this thesis is to obtain a better understanding of the nature of inelasticity in NC metals by simulating multiaxial deformation at the atomistic resolution, and developing methods to interpret the results in ways that would be useful from a continuum constitutive modeling viewpoint. First, we have presented a novel, statistical mechanics-based approach to unambiguously resolve the elastic-plastic transition as an avalanche in the proliferation of mobile defects. This approach is applied to nanocrystalline Cu to explore the influence of pressure and multiaxial stress states on the inelastic deformation behavior. The results suggest that initial yield in nanocrystalline Cu under biaxial loading is only weakly anisotropic in the 5 nm grain size regime, and that plastic flow evolves in a direction normal to the von Mises yield surface. However, triaxial deformation simulations reveal a significant effect of the superimposed hydrostatic stress on yielding under shear. These results are analyzed in detail in order to assess the influence of pre-existing internal stresses and interfacial excess volume on the inelastic deformation behavior. Further, we have studied the effects of imposed hydrostatic pressure on the shear deformation behavior of Cu bicrystals containing symmetric tilt interfaces, as well as Cu nanocrystals of different grain sizes. Most interfaces exhibit an increase in shear strength with imposed compressive hydrostatic pressure. However, for some interfaces, this trend is reversed. Neither the sign nor the magnitude of the pressure-induced elevation in shear strength appears to correlate with interface structure or particular deformation mechanism(s). In Cu nanocrystals, we observe that imposed compressive pressure leads to strengthening under shear deformation, and the effect of imposed pressure on the shear strength becomes stronger with increase in grain size or temperature. Activation parameters for shear deformation have been computed for these nanocrystals, and computed values seem to agree with existing experimental and theoretical estimates. Finally, we have proposed some modifications to conventional isothermal molecular dynamics algorithms, in order to isolate dislocation nucleation events from interfacial sources, and thereby permit explicit computation of the activation parameters for such events.

Span-to-depth ratio is an important bridge design parameter that affects structural behaviour, construction costs and aesthetics. A study of 86 constant-depth girders indicates that conventional ratios have not changed significantly since 1958. These conventional ratios are now questionable, because recently developed high-strength concrete has enhanced mechanical properties that allow for slenderer sections. Based on material consumption, cost, and aesthetics comparisons, the thesis determines optimal ratios of an 8-span highway viaduct constructed with high-strength concrete. Three bridge types are investigated: cast-in-place on falsework box-girder and solid slabs, and precast segmental span-by-span box-girder. Results demonstrate that total construction cost is relatively insensitive to span-to-depth ratio over the following ranges of ratios: 10-35, 30-45, and 15-25 for the three bridge types respectively. This finding leads to greater freedom for aesthetic expressions because, compared to conventional values (i.e. 18-23, 22-39, and 16-19), higher ranges of ratios can now be selected without significant cost premiums.

Experiments were performed to examine the shear resistance of heavily reinforced I-beams. Six I-beams with identical cross sections were constructed using high strength self-consolidating concrete, and were tested under monotonic anti-symmetric loading. All specimens had almost the same amount of longitudinal reinforcement, which provided sufficient flexural capacities. There were two variables: shear span and shear reinforcement ratio. Test results showed that ACI code was too conservative in predicting the shear strengths of heavily shear reinforced I-beams, and the shear strength limit for deep beams should be increased to account for the benefit of high strength concrete. However, doubling the amount of stirrups did not improve the ultimate shear resistance much. The three beams that contained around 2.45% stirrups showed over-reinforced shear failures. Longitudinal flange cracking occurred to every specimen due to lack of cross tie reinforcement in the flanges, and it was believed to have reduced the ultimate shear strength.