Additive friction stir deposition (AFSD) is an emerging solid-state additive manufacturing process that leverages the friction stir principle to deposit porosity-free material. The unique flow of material that allows for the transformation of bar stock into a near-net shape part is driven by the non-linear heat generation mechanisms of plastic deformation and sliding frictional heat generation. The magnitude of these mechanisms, and hence the total applied thermal power, implicitly depend on the thermal state of the system, forcing power input to become a dependent variable. This is not the case in other 3D printing methods; thermal power can be controlled independently. In this work, the heat generation in AFSD is explored, and its transfer is quantified. In particular, the time-dependent ratio between the amount of conduction into the AFSD tool versus into the substrate is quantified. It was found for the conditions tested with a single-piece AFSD tool, conduction up the tool was on the order of the conduction into the stir. For a more modern three-piece tool, the ratio between the tool and the substrate varied between 0.3-0.1. It was also found that traversing faster resulted in more heat flux into the substrate as would be expected by moving heat source modeling. The total heat generated was also quantified as being equal to between 60% and 80% of the mechanical spindle power depending on the tool type and the exact process conditions. That ratio was found to be time-invariant. At the same time, this changing heat flux ratio was shown to dramatically alter thermocouple measurements in the tool, showing the uncertainty of that method of process control. The contact state between the stir and the tool was treated as a thin conductive layer and a contact heat transfer coefficient was calculated on the order of 20 frac{kW}{m^2K}. The limitations of this treatment were found to occur when a significant amount of the heat generation came from frictional heating rather than plastic deformation. This implies that any measurement conducted in the tool is related to the stir by a complex function driven by the state of the stir; showcasing the need for more well-understood in-situ monitoring. Finally, some of the ideas about thermal control are applied to a case study on the repair of corroded through holes using AFSD to restore fatigue life. It was found that modifying the thermal boundary conditions and applying active cooling at the end of the repair could improve the fatigue life drastically. This was due to less time spent in a thermally active region leading to less heterogeneous nucleation and less grain boundary nucleation. This more preferred microstructure morphology led to a change in the fracture mode and increased the number of cycles to crack initiation and the number of cycles after crack initiation. / Doctor of Philosophy / Metal 3D printing of industrially relevant aluminum alloys is plagued with problems. Additive friction stir deposition seems well posed to overcome some of the problems associated with aluminum printing. Being able to 3D print these alloys with properties that are as good as traditional manufacturing offers a large potential cost and time savings over traditional manufacturing for the aerospace industry (e.g. Boeing, Lockheed Martin, U.S. Navy). For these components to be part of a plane, the manufacturer must prove the components were made the same way print-to-print regardless of the actual shape of the component being made. This dissertation focuses on the key metallurgical variable of temperature and explores how thermal energy is generated and where that energy goes in to the system. The key takeaway is, that without precise knowledge of the total heat generated and the entire thermal system, assurances about processing temperature cannot be made. An exploration of heat generation and metrics about its dispersion are presented. This is followed by a study on repairing structural components while changing the thermal system to understand its effects.

Recent global efforts have focused on developing new lightweight alloys specifically designed for high-pressure die casting (HPDC) processes, aiming to achieve the lightweight of electrified vehicles. HPDC offers a distinct advantage by allowing the production of neat-net-shape automotive components, minimizing the need for further processing. An inherent characteristic of HPDC is its rapid cooling rates, making the understanding and characterization of the thermophysical properties of these newly developed lightweight alloys under high cooling rates a must. These properties have a significant effect on controlling the HPDC process and developing suitable filling and solidification models to simulate the HPDC process intricacies for commercial production adaptation. The thermophysical properties of these alloys are shown to exhibit considerable variability with temperature, particularly under rapid solidification conditions, like in HPDC. Hence, an essential step in developing such alloys is to thoroughly investigate the variation of their thermophysical properties with temperature under high cooling rates. To fulfill such a need, an experimental setup has been developed to allow the solidification of molten metal samples under varying cooling rates using a set of impinging water jets. An inverse heat transfer algorithm has been developed to estimate the thermal conductivity and thermal diffusivity as a function of the temperature of the solidifying samples under high cooling rates. To validate the accuracy of the inverse heat transfer algorithm and the experimental methodology, a set of experiments has been carried out using pure Tin, which is a well-characterized material. Its thermal diffusivity and thermal conductivity are readily available in the literature. The estimated thermal diffusivity and thermal conductivity of Tin have been compared with the published data. The estimated thermal diffusivity and conductivity of the solid phase were in good agreement with the published values. A maximum deviation ranging from +10.1% to -3.47% was observed in the estimated thermal diffusivity. The maximum deviation in the estimated thermal conductivity was between +7.8% and -13.6%. Higher deviations have been observed in the estimated thermal diffusivity and conductivity of the liquid phase with deviations in the range of +33.71% to -4.86% and +0.76% to 26.53%, respectively. The higher deviations observed for the liquid phase might be attributed due to the natural convection that developed in the tested liquid sample. The effect of natural convection was examined using a set of numerical simulations that confirmed the existence of a convection-induced movement within the liquid phase. A sensitivity analysis was carried out to examine the impact of the accuracy of thermocouple positions and the effect of temperature sensing accuracy on the estimated thermal properties. / Thesis / Master of Applied Science (MASc) / An inverse heat transfer algorithm along with an experimental setup has been developed to estimate the temperature-dependant thermophysical properties during solidification of metallic alloys under high cooling rates. To verify the accuracy of the developed algorithm and the experimental setup the estimated thermal conductivity and diffusivity of pure Tin have been compared with data available in the literature. The results showed reasonable agreement.

The objective of this work was to design, analyze and test a fast response fiber-optic temperature probe and sensor. The sensor is intended for measuring rapid temperature changes such as produced by a blast wave formed by a detonation. This work was performed in coordination with Luna Innovations Incorporated, and the design is based on extensions of an existing fiber-optic temperature sensor developed by Luna. The sensor consists of a glass fiber with an optical wafer attached to the tip. A basic description of the principles behind the fiber-optic temperature sensor and an accompanying demodulation system is provided. For experimental validation tests, shock tubes were used to simulate the blast wave experienced at a distance of 3.0 m from the detonation of 22.7 kg of TNT. The flow conditions were predicted using idealized shock tube theory. The temperature sensors were tested in three configurations, flush at the end of the shock tube, extended on a probe 2.54 cm into the flow and extended on a probe 12.7 cm into the flow. The total temperature was expected to change from 300 K to 1130 K for the flush wall experiments and from 300 K to 960 K for the probe experiments. During the initial 0.1 milliseconds of the data the temperature only changed 8 K when the sensors were flush in the end of the shock tube. The sensor temperature changed 36 K during the same time when mounted on a probe in the flow. Schlieren pictures were taken of the flow in the shock tube to further understand the shock tube environment. Contrary to ideal shock tube theory, it was discovered that the flow did not remain stagnant in the end of the shock tube after the shock reflects from the end of the shock tube. Instead, the effects of turbulence were recorded with the fiber-optic sensors, and this turbulence was also captured in the schlieren photographs. A fast-response thermocouple was used to collect data for comparison with the fiber-optic sensor, and the fiber-optic sensor was proven to have a faster response time compared to the thermocouple. When the sensors were extended 12.7 cm into the flow, the fiber-optic sensors recorded a temperature change of 143 K compared to 38 K recorded by the thermocouple during the 0.5 millisecond test. This corresponds to 22% of the change of total temperature in the air recorded by the fiber-optic sensor and only 6% recorded by the thermocouple. Put another way, the fiber-optic sensor experience a rate of temperature change equal to 2.9x105 K/s and the thermocouple changed at a rate of 0.79x105 K/s. The data recorded from the fiber-optic sensor also contained much less noise than the thermocouple data. An unsteady finite element thermal model was created using ANSYS to predict the temperature response of the sensor. Test cases with known analytical solutions were used to verify the ANSYS modeling procedures. The shock tube flow environment was also modeled with Fluent, a commercially available CFD code. Fluent was used to determine the heat transfer between the shock tube flow and the sensor. The convection film coefficient for the flow was predicted by Fluent to be 27,150 W/m2K for the front of the wafer and 13,385 W/m2K for the side. The Fluent results were used with the ANSYS model to predict the response of the fiber-optic sensor when exposed to the shock tube flow. The results from the Fluent/ANSYS model were compared to the fiber-optic measurements taken in the shock tube. It was seen that the heat flux to the sensor was slightly over-predicted by the model, and the heat losses from the wafer were also over-predicted. Since the prediction fell within the uncertainty of the measurement, it was found to be in good agreement with the measured values. Inverse heat transfer methods were used to determine the total temperature of the flow from the measured data. Both the total temperature and the film coefficient were determined simultaneously during this process. It was found that for short testing times, there were many possible solutions. In order to obtain ultimate success with this method, the uncertainty of the demodulation system must be improved and/or the simple analytical thermal model used to predict the response of the sensor needs to match the physical sensor. Whenever possible, longer testing times should be employed. Promising suggestions for extending this approach are provided. / Ph. D.

The objective of this work is to apply the method of variation of parameters to various direct and inverse nonlinear, multimode heat transfer problems. An overview of the general method of variation of parameters is presented and applied to a simple example problem. The method is then used to obtain solutions to three specific extended surface heat transfer problems: 1. a radiating annular fin, 2. convective and radiative exchange between the surface of a continuously moving strip and its surroundings, and 3. convection from a fin with temperature-dependent thermal conductivity and variable cross-sectional area. The results for each of these examples are compared to those obtained using other analytical and numerical methods. The method of variation of parameters is also applied to the more complex problem of combined conduction-radiation in a one-dimensional, planar, absorbing, emitting, non-gray medium with non-gray opaque boundaries. Unlike previous solutions to this problem, the solution presented here is exact. The model is verified by comparing the temperature profiles calculated from this work to those found using numerical methods for both gray and non-gray cases. The combined conduction-radiation model is then applied to determine the temperature profile in a ceramic thermal barrier coating designed to protect super alloy turbine blades from large and extended heat loads. Inverse methods are implemented in the development of a non-contact method of measuring the properties and temperatures within the thermal barrier coating. Numerical experiments are performed to assess the effectiveness of this measurement technique. The combined conduction-radiation model is also applied to determine the temperature profile along the fiber of an optical fiber thermometer. An optical fiber thermometer consists of an optical fiber whose sensing tip is coated with an opaque material which emits radiative energy along the fiber to a detector. Inverse methods are used to infer the tip temperature from spectral measurements made by the detector. Numerical experiments are conducted to assess the effectiveness of these methods. Experimental processes are presented in which a coating is applied to the end of an optical fiber and connected to an FTIR spectrometer. The system is calibrated and the inverse analysis is used to infer the tip temperature in various heat sources.

The flow and heat transfer within compressor rotor cavities of aero-engines is a conjugate problem. Depending on the operating conditions buoyancy forces, caused by radial temperature difference between the cold throughflow and the hotter shroud, can influence the amount of entrained air significantly. By this, the heat transfer depends on the radial temperature gradient of the cavity walls and in reverse the disk temperatures are dependent on the heat transfer. In this thesis, disk Nusselt numbers are calculated in reference to the air inlet temperature and in comparison to a modeled local air temperature inside the cavity. The local disk heat flux is determined from measured steady-state surface temperatures by solving the inverse heat transfer problem in an iterative procedure. The conduction equation is solved on a 2D mesh, using a validated finite element approach and the heat flux confidence intervals are calculated with a stratified Monte Carlo approach. An estimate for the amount of air entering into the cavity is calculated by a simplified heat balance. In addition to the thermal characterization of the cavity, the mass exchange of the air in the cavity with the axial flow in the annular gap and the swirl distribution of the air in the cavity are also investigated.:1 Einleitung 2 Grundlagen und Literaturübersicht 2.1 Modellsystem der rotierenden Kavitäten mit axialer Durchströmung 2.2 Ergebnisgrößen 2.3 Strömung in rotierenden Kavitäten 2.4 Wärmeübertragung in rotierenden Kavitäten 2.5 Fluidtemperatur in rotierenden Kavitäten 3 Experimenteller Aufbau 4 Messtechnik 4.1 Oberflächen- und Materialtemperaturen 4.2 Lufttemperaturen 4.3 Statischer Druck 4.4 Dreiloch-Drucksonden 5 Datenauswertung 5.1 Kernrotationsverhältnis 5.2 Wärmestromdichte und Nusseltzahl 5.2.1 Finite-Elemente Modell 5.2.2 inverses Wärmeleitungsproblem 5.2.3 Anpassungsmethode 5.2.4 Testfälle zur Validierung 5.2.5 Validierung Testfall 1 und 3 - ideale Kavitätenscheibe 5.2.6 Validierung Testfall 2 - Reproduzierbarkeit 5.2.7 Validierung Testfall 4 - lokales Ereignis 5.2.8 Bestimmung der Wärmestromdichte-Unsicherheit 5.2.9 Anwendung der Anpassungsmethode auf experimentelle Daten 5.2.10 Wahl der Randbedingungsfunktion 5.2.11 Wärmeübergangskoeffizient und Nusselt-Zahl 5.2.12 Zusammenfassung 5.3 Austauschmassenstrom 6 Experimentelle Ergebnisse 6.1 Dichteverteilung in der Kavität 6.2 Massenaustausch Kavität 6.3 Wärmeübertragung in der Kavität 6.3.1 Fallbeispiel 6.3.2 Einfluss der Drehfrequenz 6.3.3 Einfluss des Massenstromes 6.3.4 Einfluss des Auftriebsparameters 6.4 Wärmeübertragung im Ringspalt 6.5 Drall im Ringspalt und der Kavität 7 Zusammenfassung und Ausblick / Die Strömung und Wärmeübertragung in den Verdichterkavitäten von Flugtriebwerken ist ein konjugiertes Problem. Durch die radialen Temperaturunterschiede in der Kavität wird die Menge der in die Kavität strömenden Luft stark beeinflusst. Somit ist die Wärmeübertragung abhängig von den radialen Temperaturgradienten der Scheibenwände und umgekehrt ist die Scheibentemperatur abhängig von der Wärmeübertragung. Die Nusselt-Zahl in diesem System wurde aufgrund der schwierigen Zugänglichkeit in der Historie auf die eine Referenztemperatur vor der Kavität bezogen. Dies ist insofern problematisch, da hierdurch die thermischen Verhältnisse unterschätzt werden können. In dieser Arbeit wird ein neuer Ansatz zu Berechnung der Nusselt-Zahl mithilfe einer modellierten lokalen Lufttemperatur innerhalb der Kavität verwendet. Die lokale Wärmestromdichte auf der Scheibenoberfläche wird mithilfe eines validierten zweidimensionalen rotationssymmetrischen Finite-Element Modells auf der Grundlage von gemessenen Oberflächentemperaturen berechnet. Dies stellt ein inverses Wärmeleitungsproblem dar, welches mithilfe einer Anpassungsmethode gelöst wurde. Die Auswirkung der Messunsicherheit der Temperaturmessung auf die berechnete Wärmestromdichte wird durch eine geschichtete Monte-Carlo-Simulation, nach dem Ansatz der LHC-Methode, untersucht. Neben der thermischen Charakterisierung der Kavität wird zudem der Massenaustausch der Luft in der Kavität mit der axialen Durchströmung im Ringspalt sowie die Drallverteilung der Luft in der Kavität untersucht.:1 Einleitung 2 Grundlagen und Literaturübersicht 2.1 Modellsystem der rotierenden Kavitäten mit axialer Durchströmung 2.2 Ergebnisgrößen 2.3 Strömung in rotierenden Kavitäten 2.4 Wärmeübertragung in rotierenden Kavitäten 2.5 Fluidtemperatur in rotierenden Kavitäten 3 Experimenteller Aufbau 4 Messtechnik 4.1 Oberflächen- und Materialtemperaturen 4.2 Lufttemperaturen 4.3 Statischer Druck 4.4 Dreiloch-Drucksonden 5 Datenauswertung 5.1 Kernrotationsverhältnis 5.2 Wärmestromdichte und Nusseltzahl 5.2.1 Finite-Elemente Modell 5.2.2 inverses Wärmeleitungsproblem 5.2.3 Anpassungsmethode 5.2.4 Testfälle zur Validierung 5.2.5 Validierung Testfall 1 und 3 - ideale Kavitätenscheibe 5.2.6 Validierung Testfall 2 - Reproduzierbarkeit 5.2.7 Validierung Testfall 4 - lokales Ereignis 5.2.8 Bestimmung der Wärmestromdichte-Unsicherheit 5.2.9 Anwendung der Anpassungsmethode auf experimentelle Daten 5.2.10 Wahl der Randbedingungsfunktion 5.2.11 Wärmeübergangskoeffizient und Nusselt-Zahl 5.2.12 Zusammenfassung 5.3 Austauschmassenstrom 6 Experimentelle Ergebnisse 6.1 Dichteverteilung in der Kavität 6.2 Massenaustausch Kavität 6.3 Wärmeübertragung in der Kavität 6.3.1 Fallbeispiel 6.3.2 Einfluss der Drehfrequenz 6.3.3 Einfluss des Massenstromes 6.3.4 Einfluss des Auftriebsparameters 6.4 Wärmeübertragung im Ringspalt 6.5 Drall im Ringspalt und der Kavität 7 Zusammenfassung und Ausblick