A detailed metallurgical analysis was conducted to correlate microstructure to axial strain-controlled high cycle fatigue of Ti-6Al-4V forgings made from cold isostatic pressed and sintered preforms of blended element powder metallurgy (BEPM) incorporating hydrogenated titanium. Analysis included fractographic examination by SEM, microstructure examination by optical microscopy, texture examination via EBSD, chemical analysis and fatigue strain mapping via digital image correlation (DIC). From a literature review and observations of findings, factors that were of primary concern were: maximum pore diameter, primary α volume fraction, primary α width, primary α particle count, oxygen equivalency (OE) and texture of the α phase. The primary α volume fraction was found to have the single most influential effect on fatigue, whereby decreasing volume fraction increased fatigue life. Using statistical analysis, multivariable regression analyses were performed to evaluate combinations of predictors on fatigue life. The resulting outcome of volume fraction and maximum pore diameter, having a 3.3 to 1 weighting, was the most significant at predicting the fatigue response. Improving fatigue life of forged Ti-6Al-4V made from BEPM should thus be primarily focused on microstructure refinement. It is suggested future experimentation also consider the effects of the number of primary α particles and OE when modeling fatigue strength. / Thesis / Master of Applied Science (MASc) / The mechanical properties of a metal are dictated primarily by the metal’s microstructure. The microstructure of a metal made from metal powder that has been pressed and heated to bind the powder together generally contains residual porosity. This generally leads to a reduction in metal fatigue resistance versus a metal that is pore-free. In studying metal fatigue of a titanium alloy made from metal powder, the resistance to metal fatigue varied considerably and did not achieve the same resistance of pore-free material, despite the titanium alloy in question being nearly pore-free. This titanium alloy was studied to determine what the cause of the poor metal fatigue resistance was. Through a methodical testing program, it was determined that volume fraction of a particular crystalline phase in the microstructure was more damaging than the pores themselves.

The goal of this thesis is to improve the predictive capability of Finite element (FE) by gathering data from experimental test and implement the characteristics into the material model that is used. FE is a commonly used method to predict the mechanical behavior of materials and components during applied forces. Therefore, it’s an important part of product development since it gives an opportunity to lower the costs as well as saving resources since it reduces the number of experimental tests. The method for this thesis was to first simulate tensile tests in Abaqus and then to analyze its results. Once all the simulations were done, we replicated the simulation with experimental tests. This was done with DIC (Digital Image Correlation) to help gather data. Since the goal of this thesis is to see how the predictive capability of the FEM-simulation can be improved the results are compared and discussed to see what from the FEM-simulation matches the DIC results and what does not. This will help understand what in the material model that needs to be changed to better match the testing. DIC is a non-contact method that is used to measure deformations and strain locally over an area which results in a more detailed view of the mechanical behavior of the material. The idea of using DIC during this thesis is to sample enough valuable data and apply it to the original material model of the FE-simulations to increase the predictive capability. After the results from the experimental tests were analyzed it was clear that there were both resemblances and differences in the results, for example the Young’s modulus in the FEM-calculations was higher than it was for the experimental tests, Yield strength was lower in the FEM-calculations compared to the experimental tests, maximum load at fracture was lower in the FEM-calculations compared to the experimental tests and elongation was lower in the FEM-calculations compared to the experimental tests. The FEM-calculations were based of the assumptions that the material was homogenous but that wasn’t the case for the experimental tests. Due to the strain varying over the tests the material model could be improved by adding a statistical variation, to all the elements to give them varying mechanical properties simulate how the strain vary more correctly over the specimen.

No description available.

No description available.

No description available.

No description available.

No description available.

No description available.

No description available.

This thesis focuses on the use of scaled physical experiments to better understand the development and long-term evolution of fault systems that are otherwise impossible to observe directly. The document is divided into three chapters. The first chapter documents the implementation of an inexpensive stereo vision method for acquiring high resolution three-dimensional strain data for table-top experiments. The second chapter applies the stereo vision method to a tectonic problem—the development of slip partitioning in obliquely loaded crustal systems. Slip partitioned fault systems accommodate oblique convergence with different slip rake on two or more faults and are well documented in the crust. In this chapter, we simulate oblique convergence using blocks with 30° dipping contacts under wet kaolin clay. The experiments reveal three styles of slip partitioning development—contingent upon convergence angle and the presence or absence of a pre-existing vertical fault. Across all experiments, the slip rates along slip-partitioned faults vary temporally suggesting that the faults continuously adjust to conditions produced by the other fault. The lack of steady state in the experiments suggests that slip-partitioned crustal systems may also evolve with oscillating behavior rather than developing a single efficient active fault structure to accommodate oblique convergence. The third chapter documents rheological tests of wet kaolin for applications to crustal deformation experiments. This chapter investigates thixotropy in the clay as well as the role of grain size distribution and water content on its shear strength.