Dry High speed and wet milling strategies have both been used to machine hardened die and mold H13 tool steel (HRC 45-58). The TiAlCrSiYN-based family of PVD coatings prepared with various architectures (mono-, multi- and multilayer with an TiAlCrN interlayer) were studied to evaluate the coating micro-mechanical properties that affect tool life during dry high-speed milling of H13 tool steel. A systematic design of varying TiAlCrN interlayer thickness within a multilayer coating structure was developed and its influence on coating properties and cutting performance was investigated. A comprehensive characterization of the coatings was performed using a transmission electron microscope (TEM), focused ion beam (FIB), scanning electron microscope (SEM), X-ray powder diffraction (XRD), room-temperature nanoindentation, a nano-impact, ramped load scratch and a repetitive load wear test. The incorporation of an interlayer into the multilayer coating structure was found to increase the crack propagation resistance (CPRs) to 5.8 compared to 1.9 for the multilayer and 1.6 for the monolayer coatings, which resulted in a 60% tool life increase. The wear test at a load of 1.5 N showed that although the 500nm interlayer exhibited the best coating adhesion, a decline in the H3/E2 ratio was observed to worsen the machining performance. An approximate 40% increase in the tool life was achieved with the 300 nm interlayer by obtaining a balance between mechanical and adhesion properties. To investigate the tool performance during the wet milling of hardened tool steels, the (AlCrN-TiAlN) bi-layer PVD coating was post-treated by WPC (Wide Peening Cleaning) at various pressures and times. Fatigue resistance of the coating following the application of post treatment was observed to improve as the micro-mechanical characteristics (such as H3/E2 ratio, yield stress) were increased. A deterioration in the coating’s adhesion with increasing WPC pressure was also observed as measured by wear test applying a load of 1 N. Through experimentation a balance between fatigue resistance and adhesion was found with tool life being improved by 35% at a WPC applied pressure of 0.2 MPa. / Dissertation / Doctor of Philosophy (PhD) / Over the last 50 years, PVD (physical vapor deposition) coatings have played an increasingly important role in manufacturing where tool cost takes up 3% of the total expenses of the production process. Optimization of these coatings can expedite production wherever machining is conducted under extreme cutting conditions and consequent high material removal rates. These considerations assert significant importance on conducting research on PVD coating development specifically for milling of H13 tool steel, the material widely used in the mold and die industry. This research work seeks to enhance the micro-mechanical and adhesion properties of PVD coatings through architectural design and careful process development while relating desired properties to the high-performance milling of H13 tool steel.

<p>Failure of bi-material interfaces is studied with the aim to quantify the influence of the induced stress concentrations on the strength of the interfaces. A simple point-stress criterion, used in conjunction with finite element calculations, is evaluated to provide strength predictions for bi-material bonded joints and inserts in polymer foam. The influence of local stress concentrations on the initiation of fracture at open and closed wedge bi-material interfaces is investigated. The joint combinations are analysed numerically and the strength predictions obtained from the point-stress criterion are verified in experiments. </p><p>The predictions are made using a simple point-stress criterion in combination with highly accurate finite element calculations. The point-stress criterion was known from earlier work to give accurate predictions of failure at cracks and notches but had to be slightly modified to become applicable for the studied configurations. The criterion showed to be generally applicable to the bi-material interfaces studied herein. Sensible predictions for the tendentious strength behaviour could be made with reasonable accuracy, including the prediction of crossover from local, joint-induced failure to global failure. </p><p>To study the micromechanical properties of a cellular solid with arbitrary topology, various models of a closed-cell foam are created on the basis of random Voronoi tessellations. The foam models are analysed using the finite element method and the effective elastic properties of the model cellular solids are determined. The calculated moduli are compared to the properties of a real reference foam and the numerical results show to be in very good agreement. </p><p>The mechanical properties of closed-cell, low-density cellular solids are governed by the stiffnesses of the cell edges and the cell faces. Models of idealised foam models with planar cell faces, cannot account for the curved faces found on some metal and polymer foams. Finite element models of closed-cell foams were created to analyse the influence of cell face curvature on the stiffness of the foam. By determining the elastic modulus for foams with non-planar cell faces, the effect of cell face curvature could be analysed as a function of the relative density and the distribution of solid material between cell edges and faces. </p><p>Foam models were generated from disturbed point distribution lattices and compared to models obtained from random distributions. The aim was to analyse if and how the geometry of the cells and their spatial arrangement influences the mechanical properties of a foam. The results suggest that the spatial arrangement and the geometry of the cells have significant influence on the properties of a foam. The elastic properties calculated for models from disturbed foam structures underestimated the elastic moduli of the foam, whereas models from random structures provided results which were in very good agreement with a reference foam.</p>

The microelectronics industry requires continuous advances due to ever-evolving technology and the corresponding need for higher density substrates with smaller features. Specifically, new dielectric materials with enhanced electrical properties are needed. At the same time, adhesion must be maintained in order to preserve package reliability and mechanical performance. As a result, this research investigates the use of thin glass sheets as an alternative substrate material as it offers a number of advantages including coefficient of thermal expansion similar to silicon, good dielectric properties and optical transparency to assist in the alignment of buried features. As part of this project it was necessary to deposit metallic coatings onto the glass sheets to create electrical tracks, pads and microvias. In order to meet these requirements, the metallisation of both smooth as received glass surfaces and surfaces roughened by laser machining using electroless copper and nickel deposition were investigated. This study resulted in a number of important conclusions about the roles of chemical bonding and mechanical anchoring in both the adhesion and catalyst adsorption, that are key factors in the electroless metallisation process.....

Les alliages de titane sont largement utilisés dans le secteur de l’aéronautique. Cependant,ces alliages sont très sensibles aux gammes d’élaboration et de mises en forme. Cesdernières ont une grande influence sur l’intégrité de surface des produits finis, ce qui aun impact sur la durée de vie des pièces en service. Il est donc nécessaire de maîtriser lesprocédés afin de pouvoir définir la tenue en service des pièces.Dans ces travaux, les différentes intégrités de surface sont décrites en termes d’évolutionmicrostructurale, de contraintes résiduelles et de micro-géométrie. Des essais de fatigueen flexion 4 points sont réalisés pour tester les performances mécaniques de ces surfaces.Nous avons remarqué une bonne cohérence entre les modèles reliant l’intégrité de surfaceet la tenue en fatigue déterminée expérimentalement.De plus, étant donné que les alliages de titane ont des microstructures complexes etpeuvent être multiphasés, nous nous sommes aussi intéressés au caractère hétérogènede ces matériaux principalement dans l’analyse de contraintes résiduelles déterminées àl’aide de la diffraction des rayons X. Nous avons remarqué que ces hétérogénéités ontun impact sur la détermination des contraintes résiduelles. De fait une méthodologiede détermination de contraintes non standard a été mise en place et validée par dessimulations utilisant un modèle d’homogénéisation auto-cohérent.Ces modèles d’homogénéisation sont intéressants d’un point de vue de la déterminationdes contraintes résiduelles par diffraction des rayons X car ils permettent la prise encompte de l’aspect multiphasé des matériaux ainsi que leur caractère anisotrope. / Titanium alloys are widely used in aeronautics industries. However, these alloys are highlysensitive to the method for elaboration and transformation processes. These processesimpact on the surface integrity of products. Therefore, they have to be controlled inorder to predict life time of structures.In this work, the study of surface integrity is focused on the description of microstructalevolution, residual stresses and micro-geometry. Four points bending tests were performedin order to determined the fatigue limit of the different studied processes. We find outa good consistency between models used to determinate lifetime from surface integrityinvestigation and experimental results.Moreover, microstructures of titanium alloys are highly complex and they often are twophasedmaterials. Consequently, we studied the heterogeneous behaviour of such materialby X-ray diffraction investigation.We found out that these heterogeneities have an impacton residual stresses determination. Therefore, a non-standard methodology was definedand validate by simulation using a micro-mechanic model : a self-consistent model.Micro-mechanical models are interesting for the residual stresses determination using Xraydiffraction because they allow to take into account heterogeneous and anisotropicbehaviours through anisotropic elasticity and anisotropic texture.

Failure of bi-material interfaces is studied with the aim to quantify the influence of the induced stress concentrations on the strength of the interfaces. A simple point-stress criterion, used in conjunction with finite element calculations, is evaluated to provide strength predictions for bi-material bonded joints and inserts in polymer foam. The influence of local stress concentrations on the initiation of fracture at open and closed wedge bi-material interfaces is investigated. The joint combinations are analysed numerically and the strength predictions obtained from the point-stress criterion are verified in experiments. The predictions are made using a simple point-stress criterion in combination with highly accurate finite element calculations. The point-stress criterion was known from earlier work to give accurate predictions of failure at cracks and notches but had to be slightly modified to become applicable for the studied configurations. The criterion showed to be generally applicable to the bi-material interfaces studied herein. Sensible predictions for the tendentious strength behaviour could be made with reasonable accuracy, including the prediction of crossover from local, joint-induced failure to global failure. To study the micromechanical properties of a cellular solid with arbitrary topology, various models of a closed-cell foam are created on the basis of random Voronoi tessellations. The foam models are analysed using the finite element method and the effective elastic properties of the model cellular solids are determined. The calculated moduli are compared to the properties of a real reference foam and the numerical results show to be in very good agreement. The mechanical properties of closed-cell, low-density cellular solids are governed by the stiffnesses of the cell edges and the cell faces. Models of idealised foam models with planar cell faces, cannot account for the curved faces found on some metal and polymer foams. Finite element models of closed-cell foams were created to analyse the influence of cell face curvature on the stiffness of the foam. By determining the elastic modulus for foams with non-planar cell faces, the effect of cell face curvature could be analysed as a function of the relative density and the distribution of solid material between cell edges and faces. Foam models were generated from disturbed point distribution lattices and compared to models obtained from random distributions. The aim was to analyse if and how the geometry of the cells and their spatial arrangement influences the mechanical properties of a foam. The results suggest that the spatial arrangement and the geometry of the cells have significant influence on the properties of a foam. The elastic properties calculated for models from disturbed foam structures underestimated the elastic moduli of the foam, whereas models from random structures provided results which were in very good agreement with a reference foam. / QC 20101011

The demands for high density, fine pitch interconnections in electronics systems has seen solder-based approaches for such interconnections miniaturized to the scale of tens of micro meters. At such a small scale, such 'micro joints' may contain only one or a few grains and the resultant mechanical behaviour may not be that for a polycrystalline aggregate, but rather for a single crystal. Since the ~-Sn matrix of SnAgCu solder has a contracted body-centred tetragonal (BCT) structure, such a solder grain is expected to demonstrate a considerably anisotropic behaviour. In such cases the reliability of a Phfree solder is strongly dependent on the local microstructural features, such as the size and orientation of the grains. This thesis presents the investigation of the evolution of microstructure within a joint or at the interface and, the influence of such microstructural features on the meso-scale mechanical behaviour of the Ph-free solder. It includes Evolution of the interface between a molten solder and the Cu substrate To form a joint, the solder alloy is heated and molten, wetting a solid under-bump metallization. After solidification, layers of brittle intermetallic compounds (IMCs) are formed at the interface. In this project, facilities were set up to obtain interfacial reactants at an arbitrary moment of the liquid/solid reaction. Formation and evolution ~ during reflow of SnCu IMCs at the interface between the molten SnAgCu alloy and the Cu UBM was captured and presented for the first time. Formation of phases and IMCs with the body of a liquid SnAgCu solder during solidification The formation behaviour of basic components for a SnAgCu grain (including Sn dendrites, AIDSn and Cu6Sns IMCs) during solidification was investigated. Relationships between the growth behaviour of these components and their internal lattice orientation were studied. The characteristic growth and coupling of AIDSn IMCs and the Sn matrix to form eutectics has been elaborated and presented in this study for - 1- the first time. Based on the results, the forming process of a eutectic SnAgCu grain under the non-equilibrioum solidification condition was illustrated; and major factors that determine the lattice-orientation, size and substructure of the grain were discussed. Meso- and Micro- scale mechanical behaviour of a SnAgCu solder joint To study the size effect on the microstructure, and subsequently, the meso-scale mechanical behaviour, solder joints were manufactured with varying geometries. Shearing tests were performed on these meso-scale joints. The results first demonstrated that the anisotropic characteristics of a SnAgCu grain play an important role in the mechanical behaviour of both a meso-scale solder joint and the adjacent interfacial IMCs. To further investigate the micro-scale deformation and damage mechanisms, micro-mechanical tests were preformed within a SnAgCu grain. Constitutive equations for a SnAgCu grain Based on the experimental results, a crystal model was established to describe the local microstructure-dependent mechanical behaviour. The constitutive equation was implemented by means of the finite element approach, and applied in solder joints of a Flip Chip (FC) package by a multi-scale method. To describe the crystal behaviour at the higher temperature, the model was improved to account for deformations due to vacancy diffusion and thermal expansion. This model was integrated by an implicit approach, and implemented in a full three dimension (3D) finite element (FE) model.

Deployable structures made from ultra-thin composite materials can be folded elastically and are able to self-deploy by releasing the stored strain energy. Their lightness, low cost due to smaller number of components, and friction insensitive behaviour are key attractions for space applications. This dissertation presents a design methodology for lightweight composite booms with multiple tape-spring hinges. The whole process of folding and deployment of the tape-spring hinges under both quasi-static and dynamic loading has been captured in detail through finite element simulations, starting from a micro-mechanical model of the laminate based on the measured geometry and elastic properties of the woven tows. A stress-resultant based six-dimensional failure criterion has been developed for checking if the structure would be damaged. A detailed study of the quasi-static folding and deployment of a tape-spring hinge made from a two-ply plain-weave laminate of carbon-fibre reinforced plastic has been carried out. A particular version of this hinge was constructed and its moment-rotation profile during quasi-static deployment was measured. Folding and deployment simulations of the tape-spring hinge were carried out with the commercial finite element package Abaqus/Explicit, starting from the as-built, unstrained structure. The folding simulation includes the effects of pinching the hinge in the middle to reduce the peak moment required to fold it. The deployment simulation fully captures both the steady-state moment part of the deployment and the final snap back to the deployed configuration. An alternative simulation without pinching the hinge provides an estimate of the maximum moment that could be carried by the hinge during operation. This moment is about double the snap-back moment for the particular hinge design that was considered. The dynamic deployment of a tape-spring hinge boom has been studied both experimentally and by means of detailed finite-element simulations. It has been shown that the deployment of the boom can be divided into three phases: deployment; latching, which may involve buckling of the tape springs and large rotations of the boom; and vibration of the boom in the latched configuration. The second phase is the most critical as the boom can fold backwards and hence interfere with other spacecraft components. A geometric optimisation study was carried out by parameterising the slot geometry in terms of slot length, width and end circle diameter. The stress-resultant based failure criterion was then used to analyse the safety of the structure. The optimisation study was focused on finding a hinge design that can be folded 180 degrees with the shortest possible slot length. Simulations have shown that the strains can be significantly reduced by allowing the end cross-sections to deform freely. Based on the simulations a failure-critical design and a failure-safe design were selected and experimentally verified. The failure-safe optimised design is six times stiffer in torsion, twice stiffer axially and stores two and a half times more strain energy than the previously considered design. Finally, an example of designing a 1 m long self-deployable boom that could be folded around a spacecraft has been presented. The safety of this two-hinge boom has been evaluated during both stowage and dynamic deployment. A safe design that latches without any overshoot was selected and validated by a dynamic deployment experiment.

Dans un turboréacteur civil, le contact aube/disque de la turbine basse pression est soumis à un cyclage thermomécanique dû aux dilatations et déplacements différentiels des pièces pendant les phases de vol. Ce cyclage implique des micro-mouvements alternés relatifs, c’est-à-dire du fretting, à l’interface aube/disque. Le fretting à l’étude ici concerne un contact céramique-métal, en vue de comprendre le comportement tribologique des futures aubes revêtues de céramique en remplacement des pièces métalliques traditionnelles. Dans un premier temps, différents revêtements sont comparés vis-à-vis de leur tenue à l’usure par fretting à la température de fonctionnement des pièces (700°C). L’alliage métallique du contrecorps est celui du clinquant protégeant le disque, à savoir l’alliage base cobalt HS25. Pour le contact HS25/céramique le plus prometteur, le taux d’usure très bas ainsi que le faible frottement observés sont associés à la formation d’une glaze layer. La glaze layer est un troisième corps formé à partir des débris d’usure qui apparaît dans des contacts frottant à haute température. Traditionnellement observée pour des contacts métal/métal, sa formation pour un contact métal/céramique est nouvelle. La glaze layer est alors étudiée en détail. D’un point de vue tribologique, on établit sa cinétique et ses conditions de formation en température et en fonction des paramètres tribologiques, afin de garantir une usure faible en conditions de vol. D’un point de vue morphologique, la glaze layer est caractérisée comme étant un matériau nanostructuré amorphe et cristallin, formé à partir de débris à la fois métalliques et oxydés. Enfin, la glaze layer nanostructurée est associée à un comportement mécanique ductile dans son domaine de stabilité, alors que les débris sont fragiles en conditions d’usure forte. La corrélation des angles d’étude de la glaze layer permet alors de connaître les modalités de sa formation, en vue d’anticiper la protection d’un contact vis-à-vis de l’usure grâce à la création d’une glaze layer. / In a civil turbojet motor, the blade/disk contact in the low pressure turbine undergoes thermomechanical cycling due to relative displacements between parts during the different flight phases. This cycling results in reciprocating micro-movements named “fretting” at the blade/disk interface. This study focuses on a ceramic versus metallic contact under fretting, aimed at describing the tribological behavior of developing ceramic-coated blades to replace phased-out metallic parts. Firstly, different ceramic coatings are compared regarding their wear resistance under fretting at in-flight temperature (700°C). The counterbody is the HS25 (cobalt-based alloy) protecting foil of the disk. The most favorable ceramic/metallic tribocouple evidences a very low wear rate as well as low friction that match the formation of a glaze layer. The glaze layer is a third body formed from wear debris in high temperature rubbed contacts. Such tribofilm has been commonly observed in metallic/metallic interfaces but its occurrence in a ceramic/metallic contact is new. Then the glaze layer is precisely characterized. Tribologically speaking, its kinetics and formation conditions are determined over temperature and tribological parameters, in order to ensure low wear under flight conditions. Morphologically, the glaze layer is a nanostructured amorphous and crystalline sintered from both metallic and oxidized worn debris. Finally, the nanostructured glaze layer is mechanically described as a ductile material in its stability domain, whereas debris from severe wear are brittle. The correlation of morphological, physico-chemical and mechanical studies enlighten the glaze layer formation criteria, with the aim of predicting glaze layer occurrence, hence wear protection for a given contact.

Composite materials show heterogeneity at different length scales. hence concurrent multiscale analysis is the only reliable method to analyze them. But unfortunately there is no concurrent multi-scale strategy that is efficient, and accurate while addressing all kinds of problems. This lack of reliability is partly because there is no micro-mechanical model which inherently keeps all relevent global information with it. This thesis tries to fill this gap. The presented micro-mechanical model not only homogenizes the micro-structure but also keeps the global information with it. Most of the micro-mechanical models in the literature extract the Representative Volume Element (RVE) from the continuum for analysis which results in loss of information and accuracy. In the present approach also, the RVE has been extracted from the continuum but with the major difference that all the macro/meso-scopic parameters are accounted for. Five macro/meso-scopic one dimensional parameters have been defined which completely define the effect of continuum. 11 for one dimensional stretch, _1 for torsion, __ (_ = 2, 3) for bending and _33 for uniform pressurization due to the presence of the continuum. Further, the above macro/meso-scopic parameters are proven, by the asymptotic, theory to be constant at a cross section but vary, in general, over the length of the fiber. Hence, the analysis is valid for any location and is not restricted to any local domain. Three major problems have been addressed: • Homogenization and analysis of RVE without any defects • Homogenization and analysis of RVE with fiber-matrix de-bonding • Homogenization and analysis of RVE with radial matrix cracking. Variational Asymptotic Method (VAM) has been used to solve the above mentioned problems analytically. The results have been compared against standard results in the literature and against 3D FEA. At the end, results for “Radial deformation due to torsion” problem will be presented which was solved “accidentally.”

Ziel dieser Arbeit ist es, eine Verbindung zwischen der Mikrostruktur teilkristalliner Polymere und derer mechanischen Eigenschaften auf der Mikro- und Nanometerskala aufzubauen. Dazu wurden Methoden der Rasterkraftmikroskopie verwendet um sowohl orts- als auch zeitaufgelöst Kristallisations-, Deformations- und Diffusionsprozesse in der Mikrostruktur von elastomerem Polypropylen (ePP) abzubilden. Die mechanischen Eigenschaften wurden simultan mit Mikrozugversuchen bestimmt. So konnte beispielsweise ein Zusammenhang zwischen abnehmender Kristall-Kristall-Distanz und einem Ansteigen des Elastizitätsmoduls während der Kristallisation nachgewiesen werden. Weiterhin war es möglich die Veränderung der nano-mechanischen Eigenschaften während der Kristallisation einzelner kristalliner Lamellen in deren direkter Umgebung mit MUSIC-mode Rasterkraftmikroskopie zu untersuchen. Laterale Querexpansion (auxetisches Verhalten) konnte bei uniaxialen Zugversuchen für die Kreuzschraffur-Struktur elastomeren Polypropylens auf der Größenskala einiger Mikrometer nachgewiesen werden. Zusätzlich wurde eine Orientierungsabhängigkeit dieses Effekts beobachtet. Außerdem wurde die Diffusion einzelner Kristalle in der Mikrostruktur von ePP beobachtet. Die Heterogenität dieser Diffusion lässt auf eine kristallin-amorph Grenzschicht um alle Kristalle schließen.