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Solid foams have been studied for years for their ability to mitigate damage from sudden impact. Small explosive attacks threaten to damage or destroy key structures in some parts of the world. A newly developed material, carbon foam, may offer the ability to mitigate the effects of such blasts. This project investigates the energy absorbing properties of carbon and polyurethane based foams in dynamic compression to illustrate their viability to protect concrete structures from the damaging effects of pressure waves from a small blast. Cellular solid mechanics fundamentals and a survey of the microscopic cellular structure of each type of foam are discussed. Experiments were performed in three strain rate regimes: low strain rate compression testing, middle strain rate impact testing, and high strain rate blast testing to reveal mechanical behavior. Experiments show a 7.62 cm (3”) thick hybrid composite layered foam sample can protect a concrete wall from a small blast.

A procedure for improved nonlinear analysis of reinforced concrete (RC) slab and shell structures is presented. The finite element program developed employs a layered thick-shell formulation which considers out-of-plane (through-thickness) shear forces, a feature which makes it notably different from most shell analysis programs. Previous versions were of limited use due to their inabilities to accurately capture out-of-plane shear failures, and because analyses were restricted to force-controlled monotonic loading conditions. The research comprising this thesis focuses on addressing these limitations, and implementing new analysis features extending the range of structures and loading conditions that can be considered. Contributions toward the redevelopment of the program include: i) a new solution algorithm for out-of-plane shear, ii) modelling of cracked RC in accordance with the Disturbed Stress Field Model, iii) the addition of fibre-reinforced concrete (FRC) modelling capabilities, and iv) the addition of cyclic and dynamic analysis capabilities. The accuracy of the program was verified using test specimens presented in the literature spanning various member types and loading conditions. The new program features are shown to enhance modelling capabilities and provide accurate assessments of shear-critical structures. An experimental program consisting of RC and FRC slab specimens under dynamic loading conditions was performed. Eight intermediate-scale slabs were constructed and tested to failure under sequential high-mass low-velocity impact. The data from the testing program were used to verify the dynamic and FRC modelling procedures developed, and to contribute to a research area which is currently limited in the database of literature: the global response of RC and FRC elements under impact. Test results showed that the FRC was effective in increasing capacity, reducing crack widths and spacings, and mitigating local damage under impact. Analyses of the slabs showed that high accuracy estimates can be obtained for RC and FRC elements under impact using basic modelling techniques and simple finite element meshes.

A procedure for improved nonlinear analysis of reinforced concrete (RC) slab and shell structures is presented. The finite element program developed employs a layered thick-shell formulation which considers out-of-plane (through-thickness) shear forces, a feature which makes it notably different from most shell analysis programs. Previous versions were of limited use due to their inabilities to accurately capture out-of-plane shear failures, and because analyses were restricted to force-controlled monotonic loading conditions. The research comprising this thesis focuses on addressing these limitations, and implementing new analysis features extending the range of structures and loading conditions that can be considered. Contributions toward the redevelopment of the program include: i) a new solution algorithm for out-of-plane shear, ii) modelling of cracked RC in accordance with the Disturbed Stress Field Model, iii) the addition of fibre-reinforced concrete (FRC) modelling capabilities, and iv) the addition of cyclic and dynamic analysis capabilities. The accuracy of the program was verified using test specimens presented in the literature spanning various member types and loading conditions. The new program features are shown to enhance modelling capabilities and provide accurate assessments of shear-critical structures. An experimental program consisting of RC and FRC slab specimens under dynamic loading conditions was performed. Eight intermediate-scale slabs were constructed and tested to failure under sequential high-mass low-velocity impact. The data from the testing program were used to verify the dynamic and FRC modelling procedures developed, and to contribute to a research area which is currently limited in the database of literature: the global response of RC and FRC elements under impact. Test results showed that the FRC was effective in increasing capacity, reducing crack widths and spacings, and mitigating local damage under impact. Analyses of the slabs showed that high accuracy estimates can be obtained for RC and FRC elements under impact using basic modelling techniques and simple finite element meshes.

Welding is a common method for joining of metal or plastic construction parts. This report describes several different weld methods in general terms. The report focuses on the GMAW method, specifically MAG welding. A case study has also been performed for the company Wenmec. The task received from the company was to compare the mechanical properties of joints welded with the tube electrode called Nittetsu SM-3A and joints welded with the homogenous electrode called ESAB Aristorod 12.63. Both types of weld joint were welded with the MAG method with an Argon based shielding gas with 18% CO2. The final task of this study is to compare the cost of these electrodes and then help Wenmec to decide which electrode that is the most cost effective. Tensile testing, impact testing and fatigue testing were performed on the weld joint samples. The hardnesses, microstructures, failure zones and chemical composition were examined with optical microscopy and SEM. The weld time, the amount of consumed electrode and the weld energy was measured during welding. These properties were similar and the differences between the different joints could be ignored. Both weld joint types showed similar microstructures and hardnesses. The microstructure was ferrite with carbides or perlite at the grain boundaries. Some silicon oxides were found in the grains. The yield strength, ultimate tensile strength and cycles to fatigue failure were similar in the two joint types, but the Aristorod weld joint showed higher impact strength and elongation at break. The chemical composition showed that the SM-3A electrode was a metal cored electrode with some additions of deoxidizing elements and a Copper coating. The Aristorod 12.63 electrode also showed the presence of deoxidizing elements and likely had a Titanium based coating. The sheet metal used as the work pieces are called Ruukki Laser 355 MC and is steel with low Carbon content, some Manganese and some impurities. The SM-3A electrode was costlier than the 12.63 electrode. This work concluded that the 12.63 electrode was a better alternative for Wenmec due to the lower cost, higher impact strength and higher elongation at break / Svetsning är en vanlig metod för att sammanfoga detaljer av metall och i vissa fall plast. Denna rapport beskriver flera olika svetsmetoder och allmänna fakta kring dem varpå rapporten fördjupas inom GMAW metoden, specifikt MAG. Ett detaljfall studeras också då företaget Wenmec gett uppdraget att jämföra mekaniska egenskaper för svetsfogar svetsade med rörelektroden Nittetsu SM-3A respektive den homogena elektroden ESAB Aristorod 12.63. Båda fogtyperna svetsades med MAG metoden och en argonbaserad skyddsgas med 18 % CO2. Till sist berör detta arbete de svetsekonomiska aspekterna för Wenmec och om företaget bör byta elektrodtyp eller inte. Mekanisk provning som utförts var dragprovning, slagprovning och utmattningsprovning. Mikrostrukturen och hårdheten i svetsfogarna jämfördes samt brottytor och kemisk sammansättning undersöktes med SEM. Vid svetsning jämfördes svetstid och materialåtgång samt den så kallade sträckenergin. Svetstekniskt var de båda svetsfogarna så lika att skillnader kunde ignoreras. Det visade sig att de båda elektroderna gav upphov till svetsgods med likadan mikrostruktur och snarlik hårdhet. Mikrostrukturen visade sig vara ferritisk med vissa mängder karbid eller perlit vid korngränserna. Partiklar i mikrostrukturen visade sig vara främst kiseloxider. Cykler till utmattningsbrott, sträckgräns och brottgräns var snarlika mellan de båda svetsfogarna medan Aristorod 12.63 hade bättre brottöjning och slagseghet. Den kemiska analysen visade att SM-3A var en metallpulverfylld rörelektrod med vissa deoxiderande tillsatser och en ytbeläggning som bestod av koppar. Aristorod 12.63 hade också vissa deoxiderande tillsatser och hade troligen en titanhaltig ytbeläggning. Stålplåten som användes som arbetsstycke var Ruukki Laser 355 MC och är ett lågkolstål med en aning mangan och andra föroreningar. De ekonomiska aspekterna visar att SM-3A är ett dyrare alternativ än 12.63. Sammantaget kom detta arbete fram till att SM-3A inte är ett attraktivt alternativ för Wenmec då slagseghet och brottöjning var sämre och elektroden dessutom var dyrare.

SOLA International, a company which manufactures optical lenses, attended the 2000 Mathematics-in-Industry Study Group (MISG) with a wish list. Topping this list was the creation of a mathematical model of a lens, which given the lens geometry and material properties, could predict the deformation of the lens when it was subjected to an impact, such as that experienced in the fracture tests lenses must pass before being approved for sale. The first steps towards such a model were taken at MISG. At MISG, a lens was modelled simply as a thin uniform thickness plate, undergoing small, linear deformations. In the first section of my thesis I extend this model by considering variable thickness plates and larger, nonlinear deformations. For this extended model I have confirmed that the result obtained at MISG, that the contact between a plate and a spherical indentor occurs at a single point, still holds. The second part of this thesis looks at the dynamic deformation, or vibration, of plates. I have developed numerical solution methods for the large amplitude vibration equations with and without the in-plane inertia terms, based on a finite difference scheme. A comparison of these solutions confirms the often used assumption that the in-plane inertia may be neglected. I have also implemented a number of solution methods from the literature, which use separation of variables techniques. Comparing these with the numerical solutions, we find that the numerical solutions better capture the multi-modal nature of the vibration - showing multiple cycles in the approximate period. Having achieved an understanding of the types of forces involved in plate deformation and vibration I consider shell theory in the final section of my thesis. While time constraints meant no dynamic results could be obtained, general nonlinear deep shell equations have been derived. The static version of these equations has then been solved, with the development of a new solution technique which combines a Taylor expansion to approximate the behaviour at the shell centre with a numerical shooting method. Various shallow shell simplifications of the deep shell equations are then discussed and solved. By comparison of the solutions obtained for the deep and shallow, linear and nonlinear equations I have been able to determine which theories apply to which geometries. A complete model of a lens needs to take into account the shape, its thickness and curvature and the material from which it is made. From the work done in this thesis we have been able to determine that a lens model would require the nonlinear theory. Whether the deep shell theory is necessary is debatable as the geometry of a typical lens falls in the grey area, where either theory could be used depending on the accuracy required. For a very accurate model, deep shell theory would be necessary; if an approximate solution obtained quickly was more useful then I suggest the use of a particular set of shallow shell equations. A full lens model would require variable thickness shell theory and the solution of the dynamic equations, neither of which has been achieved here, but the solution techniques I have developed would be applicable to these theories.

The aim of the work presented was to investigate the effects of upper bainite on impact toughness in quench and tempered low alloy plate steels. The experimental research included construction of CCT diagrams by dilatometry, verification of phases by optical microscopy (OM), Vickers hardness, scanning electron microscopy (SEM), transmission electron microscopy (TEM) on precipitates extracted by carbon replica and by electrolytic means and finally impact testing of Charpy specimens with mixed bainite:martensite microstructures. Bainite was formed in High Chromium Low Molybdenum (HCrLMo) and in High Molybdenum Low Chromium (HMoLCr) steel samples by isothermal annealing within the bainite C-curve of the respective CCT diagrams. The isothermal kinetics of the upper bainite transformation was modelled with the Johnson Mehl Avrami Kolmogorov (JMAK) model. Avrami exponents of 1.4 and 1.3 were obtained for the HCrLMo and HMoLCr steels respectively which indicated linear growth with a considerable lengthening rate of laths and negligible thickening. The measurably slower growth kinetics in the HMoLCr steel as observed in the JMAK model and the higher hardenability with reference to its CCT diagram, suggested a strong Mo alloying element effect. The stronger effect of Mo compared to Cr was attributed to a solute drag like effect. The effect of upper bainite in a tempered martensitic matrix was investigated for the following amounts of bainite; 0%, 10%, 25%, 60%, 75%, 90% and 100%. The impact toughness of the mixed bainite:martensite samples was evaluated against the toughness of 100% bainite and 100% martensite. It was demonstrated that upper bainite reduces the total absorbed impact energy by an adverse effect on crack nucleation energy and crack propagation energy. / Dissertation (MSc)--University of Pretoria, 2013. / gm2014 / Materials Science and Metallurgical Engineering / Unrestricted

M.Ing.(Electrical and Electronic Engineering) / The study investigated whether non-destructive impact testing, aided by supervised machine learning methods, could be used to identify improper roof bolt installations, related to insufficient grout coverage. The testing method involved the installation of four roof bolts, with varying installation properties, into a 1511 × 940 × 1350mm rock test block. Three fully grouted bolts served as examples of proper installations, with the fourth bolt grouted only up to half the length of the borehole serving as an improper roof bolt installation. The testing procedure involved placing sensors directly onto the bolts and mechanically impacting a chosen bolt while measuring the response on all the bolts. The focus was on gaining understanding of the working principle of the testing technique and how the measured response was influenced by the presence of signal-modifying factors of the physical test block geometry, such as changes in material properties, boundary changes, cracks or empty boreholes. It was shown that the roof bolt integrity testing method aided by supervised machine learning methods could identify and classify both properly and improperly grouted roof bolts on the small sample of test bolts, in a series of tests conducted at the CSIR Centre for Mining Innovation premises. The method was also shown to be robust enough to do so even in the presence of the signal-modifying factors of the physical test block geometry.

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The use of composite sandwich structures is rapidly increasing in the aerospace industry because of their increased strength-to-weight and stiffness-to-weight characteristics. The effects of low velocity impacts on these structures, however, are the main weakness that hinders further use of them in the industry because the damages from these loadings can often be catastrophic. Impact behavior of composite materials in general is a crucial consideration for a designer but can be difficult to describe theoretically. Because of this, experimental analysis is typically used to attempt to describe the behavior of composite sandwiches under impact loads. Experimental testing can still be unpredictable, however, because low velocity impacts can cause undetectable damage within the composites that weaken their structural integrity. This is an important issue with composite sandwich structures because interlaminar damage within the composite facesheets is typical with composites but the addition of a core material results in added failure modes. Because the core is typically a weaker material than the surrounding facesheet material, the core is easily damaged by the impact loads. The adhesion between the composite facesheets and the core material can also be a major region of concern for sandwich structures. Delamination of the facesheet from the core is a major issue when these structures are subjected to impact loads. This study investigated, through experimental and numerical analysis, how varying the core and facesheet material combination affected the flexural strength of a composite sandwich subjected to low velocity impact. Carbon, hemp, aramid, and glass fiber materials as facesheets combined with honeycomb and foam as core materials were considered. Three layers of the same composite material were laid on the top and bottom of the core material to form each sandwich structure. This resulted in eight different sandwich designs. The carbon fiber/honeycomb sandwiches were then combined with the aramid fiber facesheets, keeping the same three layer facesheet design, to form two hybrid sandwich designs. This was done to attempt to improve the impact resistance and post-impact strength characteristics of the carbon fiber sandwiches. The two and one layer aramid fiber laminates on these hybrid sandwiches were always laid up on the outside of the structure. The sandwiches were cured using a composite press set to the recommended curing cycle for the composite facesheet material. The hybrid sandwiches were cured twice for the two different facesheet materials. The cured specimens were then cut into 3 inch by 10 inch sandwiches and 2/3 of them were subjected to an impact from a 7.56 lbf crosshead which was dropped from a height of 38.15 inches above the bottom of the specimen using a Dynatup 8250 drop weight machine. The impacted specimen and the control specimen (1/3 of the specimens not subjected to an impact) were loaded in a four-point bend test per ASTM D7250 to determine the non-impacted and post-impact flexural strengths of these structures. Each sandwich was tested under two four-point bend loading conditions which resulted in two different extension values at the same 100 lbf loading value. The span between the two supports on the bottom of the sandwich was always 8 inches but the span between the two loading pins on the top of the sandwich changed between the two loading conditions. The 2/3 of the sandwiches that were tested after being impacted were subjected to bending loads in two different ways. Half of the specimens were subjected to four-point bending loads with the impact damage on the top facesheet (compressive surface) in between the loading pins; the other half were subjected to bending loads with the damage on the bottom facesheet (tensile surface). Theoretical failure mode analysis was done for each sandwich to understand the comparisons between predicted and experimental failures. A numerical investigation was, also, completed using Abaqus to verify the results of the experimental tests. Non-impacted and impacted four-point bending models were constructed and mid-span deflection values were collected for comparison with the experimental testing results. Experimental and numerical results showed that carbon fiber sandwiches were the best sandwich design for overall composite sandwich bending strength; however, post-impact strengths could greatly improve. The hybrid sandwich designs improved post-impact behavior but more than three facesheet layers are necessary for significant improvement. Hemp facesheet sandwiches showed the best post-impact bending characteristics of any sandwich despite having the largest impact damage sizes. Glass and aramid fiber facesheet sandwiches resisted impact the best but this resulted in premature delamination failures that limited the potential of these structures. Honeycomb core materials outperformed foam in terms of ultimate bending loads but post-impact strengths were better for foam cores. Decent agreement between numerical and experimental results was found but poor material quality and high error in material properties testing results brought about larger disagreements for some sandwich designs.