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<div>Fused deposition modeling (FDM) represents one of the most common techniques for rapid proto-typing in additive manufacturing (AM). This work applies image based thermography to monitor the FDM process in-situ. The nozzle temperature, print speed and print orientation were adjusted during the fabrication process of each specimen.</div><div>Experimental and numerical analysis were performed on the fabricated specimens. The combination of the layer wise temperature profile plot and temporal plot provide insights</div><div>for specimens fabricated in x, y and z-axis orientation. For the x-axis orientation build possessing 35 layers, Specimens B16 and B7 printed with nozzle temperature of 225 ➦C and</div><div>235 ➦C respectively, and at printing speed of 60 mm/s and 100 mm/s respectively with the former possessing the highest modulus, yield strength, and ultimate tensile strength. For the y-axis orientation build possessing 59 layers, Specimens B23, B14 and B8 printed with nozzle temperature of 215°C, 225°C and 235°C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and yield strength, while the latter the highest ultimate tensile strength. For the z-axis orientation build possessing 1256 layers, Specimens B6, B24 and B9 printed with nozzle temperature of 235°C, 235°C and 235°C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and ultimate tensile strength, while B24 had the highest yield strength and B9 the lowest modulus, yield strength and ultimate tensile strength. The results show that the prints oriented in the y-axis orientation perform relatively better than prints in the x-axis and z-axis orientation.</div>

High combustion temperatures are required in gas-turbine engines to achieve high cycle efficiencies. With increasing temperature, however, the life span of the turbine components are reduced. The ability to accurately predict engine component temperature as a function of combustion temperature is required to strike this balance correctly. An experimental heat transfer measurement technique is developed in this thesis, which builds on a large body of existing literature. The technique enables a detailed quantification of turbine heat transfer on test rigs which closely represent gas-turbine engine configurations. Fundamental improvements are made to existing methods, in the definition of the ‘semi- infinite limit’ for transient measurement techniques, in Infra-red camera calibration, and in thermal effusivity measurement. The improvements were developed from first principles, verified experimentally, and have been used on a world leading heat transfer rig (the FACTOR combustor-turbine interaction rig, run on the NG-Turb facility at DLR Göttingen). It was found that optimisation of a number of measurement parameters was required to minimise the measurement uncertainty. It is shown that the optimum measurement parameters are dependant, and sensitive to the specific configuration of the test rig. An experimental procedure was developed and tested, which has been ‘tuned’ for measurements on the FACTOR test rig. Despite the challenging measurement environment on the FACTOR rig, it was found that state-of-the-art heat transfer measurement uncertainties of approximately 5%, could nevertheless still be achieved, by using the new methods. General principles and rules are established which can be used to guide the design of future heat transfer measurements, with the aim of minimising measurement uncertainty.

Indiana University-Purdue University Indianapolis (IUPUI) / Fused deposition modeling (FDM) represents one of the most common techniques for rapid proto-typing in additive manufacturing (AM). This work applies image based thermography to monitor the FDM process in-situ. The nozzle temperature, print speed and print orientation were adjusted during the fabrication process of each specimen. Experimental and numerical analysis were performed on the fabricated specimens. The combination of the layer wise temperature profile plot and temporal plot provide insights for specimens fabricated in x, y and z-axis orientation. For the x-axis orientation build possessing 35 layers, Specimens B16 and B7 printed with nozzle temperature of 225 C and 235 C respectively, and at printing speed of 60 mm/s and 100 mm/s respectively with the former possessing the highest modulus, yield strength, and ultimate tensile strength. For the y-axis orientation build possessing 59 layers, Specimens B23, B14 and B8 printed with nozzle temperature of 215 C, 225 C and 235 C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and yield strength, while the latter the highest ultimate tensile strength. For the z-axis orientation build possessing 1256 layers, Specimens B6, B24 and B9 printed with nozzle temperature of 235 C, 235 C and 235 ➦C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and ultimate tensile strength, while B24 had the highest yield strength and B9 the lowest modulus, yield strength and ultimate tensile strength. The results show that the prints oriented in the y-axis orientation perform relatively better than prints in the x-axis and z-axis orientation.

Les composites thermoplastiques sont de plus en plus privilégiées dans les structures aérospatiales au vue de leur tolérance aux dommages améliorée par rapport aux résines thermodurcissables. Néanmoins, ils restent sensibles à l’impact car il produit des endommagements complexes au sein du matériau, dont le délaminage est le plus critique. La propagation de ces endommagements en compression après impact (CAI) entraîne une réduction de la tenue résiduelle. D’abord, des essais ENF ont été menés afin de déterminer la ténacité interfaciale par le biais de la méthode de la complaisance et de la technique de thermographie infrarouge. Ensuite, l’essai « Short Beam Shear » est proposé afin d’investiguer le couplage entre la fissuration matricielle et le délaminage. L’effet de la vitesse de sollicitation a été également étudié. La valeur de ténacité mesurée semble indépendante à la vitesse de sollicitation car, lors des essais réalisés, la propagation est instable. Ensuite, le comportement d’une éprouvette académique été étudié à l’aide du « Discrete Ply Model » (DPM) permettant d’enchaîner la simulation d’impact et de CAI. Ce modèle est basé sur une approche semi-discrète modélisant le délaminage et la fissuration matricielle par des éléments cohésifs, permettant de prendre en compte le couplage entre ces deux endommagements. Une vaste campagne d'essais expérimentaux d’impact et de CAI a été mise en place sur quatre empilements différents impactés à trois niveaux d’énergie. Le modèle DPM a prouvé sa capacité à prédire correctement les endommagements d’impact et de CAI. Finalement, afin de se rapprocher des conditions de structures réelles, le comportement en compression après impact d’une plaque trouée a été investigué. / High-performance thermoplastic composite have been increasingly used in aerospace applications because of their advantageous mechanical properties. Nevertheless, impact damage leads to significant reduction in structure compressive strength although damage may remain unnoticed. Delamination is the most critical damage. Short Beam Shear (SBS) test has been proposed to reproduce impact damage chronology and characterize delamination toughness. Infrared thermography is used for local measuring of fracture toughness in this unclassical test showing unstable fracture growth. Mode II fracture toughness (GIIC) values are comprised between 0.9 and 1.7 N/mm and there was no influence of the loading rate in GIIC values. Discrete Ply Model (DPM) is therefore used to model impact and compression after impact tests on laminated composite structures. Tests have been conducted in order to validate DPM capacity to capture the effects of progressive damage and failure. Impact damage and specimen’s compressive strength is well predicted by DPM. CAI damage propagation is driven by the buckling of the structure. DPM is finally employed to study impact on an industrial sample with a large diameter hole. Impact damage correlates with tests but buckling is difficult to estimate, meaning that rupture of the specimen does not correlate to tests. Nevertheless, DPM shows a good ability to predict damage in thermoplastic composite.

Une analyse du comportement thermomécanique du caoutchouc naturel est réalisée en combinant deux techniques d'imagerie quantitative. La corrélation d'images visibles sert à estimer les déformations puis l'énergie de déformation alors que des images infrarouges permettent d'estimer, via l'équation de diffusion, les quantités de chaleur mise en jeu. La construction de bilans d'énergie montre alors l'importance relative des mécanismes dissipatifs et de couplage thermomécanique. A basse fréquence pour de faibles déformations, les résultats permettent de retrouver le fameux effet d'inversion thermoélastique. A déformation plus importante, les résultats montrent une compétition sur le plan énergétique entre élasticité entropique et mécanismes de cristallisation/fusion sous contrainte. Aucun effet dissipatif significatif n'est détecté à basse comme en haute fréquence alors que dans chaque cas, sur le plan mécanique, une aire d'hystérésis caractérise la réponse cyclique du matériau. / An analysis of the thermomechanical behavior of the natural rubber is carried out by combining two quantitative imaging techniques. The digital image correlation of visible images is used to estimate the strain and then the deformation energy whereas infrared images make it possible to estimate, via the heat equation, the amounts of heat involved in the material transformation. The construction of energy balance enables us to determine the relative importance of the dissipative and thermomechanical coupling mechanisms. For low frequency and low extension ratio, the results show the famous thermoelastic inversion effect. From an energy standpoint, a competition between entropic elasticity and stress-induced crystallization/fusion mechanisms is observed for more significant extension ratios. No significant dissipative effect can be detected at low or high loading frequency whereas in each case, a stress-strain hysteresis characterizes the cyclic response of the material.