Thesis (M.S.)--Engineering, Georgia Institute of Technology, 2004. / McDowell, David, Committee Chair; Neu, Richard, Committee Member; Lee, Jim, Committee Member; Cochran, Joe, Committee Member. Includes bibliographical references (leaves 159-162).

Thesis (doctoral)--Helsinki University of Technology, 2001. / Includes bibliographical references. Also available on the World Wide Web.

Thesis (Ph.D.)--McMaster University, 2005. / Supervisor: Ken Coley. Includes bibliographical references (leaves 204-211).

The focus of this work is on the modeling and simulation of shock wave propagation in reactive metal powder mixtures. Reactive metal systems are non-explosive, solid-state materials that release chemical energy when subjected to sufficiently strong stimuli. Shock loading experiments have demonstrated that ultra-fast chemical reactions can be achieved in certain micron-sized metal powder mixtures. However, the mechanisms of rapid mixing that drive these chemical reactions are currently unclear. The goal of this research is to gain an understanding of the shock-induced deformation that enables these ultra-fast reactions. The problem is approached using direct numerical simulation. In this work, a finite element (FE) model is developed to simulate shock wave propagation in discrete particle mixtures. This provides explicit particle-level resolution of the thermal and mechanical fields that develop in the shock wave. The Ni/Al powder system has been selected for study. To facilitate mesoscale FE simulation, a new dislocation-based constitutive model has been developed to address the viscoplastic deformation of fcc metals at very high strain rates. Six distinct initial configurations of the Ni/Al powder system have been simulated to quantify the effects of powder configuration (e.g., particle size, phase morphology, and constituent volume fractions) on deformation in the shock wave. Results relevant to the degree of shock-induced mixing in the Ni/Al powders are presented, including specific analysis of the thermodynamic state and microstructure of the Ni/Al interfaces that develop during wave propagation. Finally, it is shown that velocity fluctuations at the Ni/Al interfaces (which arise due to material heterogeneity) may serve to fragment the particles down to the nanoscale, and thus provide an explanation of ultra-fast chemical reactions in these material systems.

Laser Melting (LM) is an Additive Layer Manufacturing (ALM) process used to produce three-dimensional parts from metal powders by fusing the material in a layerby- layer manner controlled by a CAD model. During LM, rapid temperature cycles and steep temperature gradients occur in the scanned layers. Temperature gradients induce thermal stresses which remain in the part upon completion of the process (i.e. residual stresses). These residual stresses can be detrimental to the functionality and structural integrity of the built parts. The work presented in this thesis developed a finite element model for the purpose of investigating the development of the thermal and residual stresses in the laser melting of metal powders. ANSYS Mechanical software was utilised in performing coupled thermal-structural field analyses. The temperature history was predicted by modelling the interaction of the moving laser heat source with the metal powders and base platform. An innovative ‘element birth and death’ technique was employed to simulate the addition of layers with time. Temperature dependent material properties and strain hardening effects were also considered. The temperature field results were then used for the structural field analysis to predict the residual stresses and displacements. Experiments involving laser melting Ti-6Al-4V powder on a steel platform were performed. Surface topography analyses using a laser scanning confocal microscope were carried out to validate the numerically predicted displacements against surface measurements. The results showed that the material strain hardening model had a direct effect on the accuracy of the predicted displacement results. Using the numerical model, parametric studies were carried out to investigate the effects of a number of process variables on the magnitude of the residual stresses in the built layers. The studies showed that: (i) the average residual stresses increased with the number of melted powder layers, (ii) increasing the chamber temperature to 300°C halved the longitudinal stresses. At 300°C, compressive stresses appeared on the Ti64 surface layer, (iii) reducing the raster length from 1 mm to 0.5 mm reduced the average longitudinal stress in the top layer by 51 MPa (0.04σy), (iv) reducing the laser scan speed from 1200 mm/s to 800 mm/s increased the longitudinal stress by 57 MPa (0.05σy) but reduced the transverse stress by 46 MPa (0.04σy).

As one category of energetic materials, impact-initiated reactive materials are able to release a high amount of stored chemical energy under high strain rate impact loading, and are used extensively in civil and military applications. In general, polymers are introduced as binder materials to trap the reactive metal powders inside, and also act as an oxidizing agent for the metal ingredient. Since critical attention has been paid on the metal / metal reaction, only a few types of polymer / reactive metal interactions have been studied in the literature. With the higher requirement of materials resistant to different thermal and mechanical environments, the understanding and characterization of polymer / reactive metal interactions are in great demand. In this study, PTFE (Polytetrafluoroethylene) 7A / Ti (Titanium) composites were studied under high strain rates by utilizing the Taylor impact and SHPB tests. Taylor impact tests with different impact velocities, sample dimensions and sample configurations were conducted on the composite, equipped with a high-speed camera for tracking transient images during the sudden process. SHPB and Instron tests were carried out to obtain the stress vs. strain curves of the composite under a wide range of strain rates, the result of which were also utilized for fitting the constitutive relations of the composite based on the modified Johnson-Cook strength model. Thermal analyses by DTA tests under different flow rates accompanied with XRD identification were conducted to study the reaction mechanism between PTFE 7A and Ti when only heat was provided. Numerical simulations on Taylor impact tests and microstructural deformations were also performed to validate the constitutive model built for the composite system, and to investigate the possible reaction mechanism between two components. The results obtained from the high strain rate tests, thermal analyses and numerical simulations were combined to provide a systematic study on the reaction mechanism between PTFE and Ti in the composite systems, which will be instructive for future energetic studies on other polymer / reactive metal systems.

A method has been developed to produce grain sizes as low as 5µm in β-CuAlNi alloys and the effect of grain size on mechanical and strain-memory properties was studied. The thermomechanical treatment procedure involved two. sequential warm working and recrystallization steps at 600° C and 800° C respectively on eutectoid alloys. Three different eutectoid alloys, two with Ms temperature of around 0°C and one with Ms = 220° C were used for the present studies. Even at fine grain sizes, the specimens produced were of single β- phase type without any second phases. Two-stage characteristic stress-strain curves were obtained for most of the specimens in both the strain memory and pseudoelastic states. It was found that the ultimate tensile strength and strain to failure increased with decreasing grain size according to a Hall-Petch relationship down to a grain size of 5µm with the exception of one alloy. Fracture strengths of 1,200 MPa and fracture strains of 10% could be obtained. It was found that the major recovery mode, whether pseudoelastic or strain memory, did not have any significant effect on the total recovery obtained. Recovery properties were not affected significantly by decreasing grain size. Approximately 86% recovery could be obtained for an initial applied strain of 5% at a grain size of around 10µm. Grain refinement increased the fatigue life considerably, possibly due to high ultimate fracture strength and ductile fracture mode. Fatigue life of 275,000 cycles could be obtained for an applied stress of 330 MPa and a steady state strain of 0.6%. Most of the fractures are due to intergranular-type brittle fracture. At fine grain sizes, transgranular-type brittle fracture and microvoid coalescence-type ductile fracture dominated the fracture mode. Oxygen segregation at grain boundaries is the possible explanation for the different mechanical properties shown by different alloys in the present work by being a major factor in causing intergranular-type fracture. / Applied Science, Faculty of / Materials Engineering, Department of / Graduate

The production of metal powders by water atomisation is a well established process, which can be used to produce a wide range of particle sizes. A careful control of the particle size distribution is necessary, to atomise powders with a high quality and at a low production cost. Therefore, it is necessary to have a substantial knowledge of the relation between operational parameters and the particle size, to be able to produce water atomised metal powders with consistent and high yields. The main purpose with this thesis was to increase the knowledge about factors which affect the mass median particle size (d50) for water atomised metal powders. The specific objectives with the study were to develop a theoretical d50 model and to investigate the relation between the particle size and the physical properties of the liquid metal. Pilot scale experiments for liquid iron showed that alloy additions of carbon and sulphur decreased the d50 value, at a maintained liquid steel temperature before atomisation. Moreover, it was indicated that the reduced particle size at increased %C and %S contents may be related to a decreased viscosity and surface tension of the liquid metal, respectively. An alternative explanation could be that raised superheats at increased carbon contents increased the total available time for atomisation, which may have contributed to a reduction of the d50 value. The theoretical d50 model developed in this work showed a very good correlation to the current experimental data. The model considers the influence of surface tension, viscosity, melt stream diameter, water pressure, water jet angle and water to metal ratio. This model was further used to analyse how the d50 value was influenced by the viscosity and the surface tension. A reduced viscosity from 4∙9 to 2∙1 mPa s decreased the d50 value with 33%. In addition, the particle size was estimated to decrease with 21% by decreasing the surface tension from 1840 to 900 mN m-1. / Q 20120529

No description available.

D. Tech. Chemical and Metallurgica Engineering. / Discusses the development highly corrosion resistant multi-functional materials for automobile applications by using laser surface alloying of aluminium substrate with a combination of metallic and ceramic powdery materials.