Burr formation and poor hole quality can be detrimental to fatigue life as well as hinder the assembly and functionality of drilled components, particularly those made from metallic-composite stacks. Following a detailed literature review, four phases of experimental work were carried out to evaluate the effects of varying cutting parameters, tool geometries/coatings, workpiece configuration and machining strategies on hole quality/integrity, burr formation and subsequent workpiece fatigue performance, following drilling of several 2-layer stack configurations (CFRP/AA2024, AA2024/AA7010 and CFRP/Ti-6A1-4V). This was complemented by the development of numerical models to predict burr formation when drilling metallic alloys. Key contributions of the research were: (i) improved understanding with regard to the influence of cutting speed and feed rate on burr formation and hole quality when drilling individual Ti-6A1-4V, AA2024 and AA7010 alloys together with various stack assemblies; (ii) identification of appropriate tool type and cutting conditions in addition to possible alternative burr suppression methods; (iii) understanding of the significance of burr formation on fatigue life of individual metallic materials and; (iv) derivation of an analytical model for entrance and interlayer burrs as well as formulation of an FE model for enhanced burr formation (entrance and exit) predictions when drilling individual metallic materials.

Understanding of the mechanism of the vibration needed to fill thin section or one with sharp edges in profile shapes and clarifying the dominant control parameters of the vibration in thin wall investment casting is key to producing sound casting (one free of misrun defects). It's also a central issue for study in this thesis. The filling capability in thin wall investment casting method was assessed in relation to metal head. It was found that the effect of the vibration on the metal head is markedly dependent on acceleration. Generally, it was observed that the metal head required to force the metal in thin sections in the casting vibrated at (1g) acceleration is approximately half that used in castings made without vibration. Two potential mechanisms were observed from the experimental result during the filling process in thin wall casting i] discontinuous propagation flow in vibration conditions; and ii] continuous propagation flow without vibration. These mechanisms may be acting to modify the contact angles between liquid metal and a wall of the mould. Experiments also showed that two features of the transition can be observed from the front of the morphology; i] a coherent liquid metal front - this occurs in thin wall investment casting when the acceleration due to vibration is less than (1g); and ii] jetting at the free surface - this occurs in thin wall investment casting when the acceleration due to vibration exceeds 1g. This is present in terms of a unifying concept, using a frequency and amplitude ( f - a ) map. The time of the vibration operation has a moderate effect on the relative filling area when the acceleration is less than 1g. However, it is more effective when the acceleration of the vibration is greater than 1g. The mathematical models comprised one-dimensional heat transfer with phase change and had an established flow field for molten A356 alloys flow in the thin section ceramic channel mould. The work was concerned with the fluidity of A356 alloys in thin wall investment casting with and without vibration in two type of filling (flowability and fillability filling types), combining heat and metal flow in addition to the simultaneous solidification stage. The results of the mathematical model, produced agreement with the experimental test carried out in the foundry and also agreed with other published data. The results on fluidity indicated that the fluidity of the molten metal was affected by mould temperature, pouring temperature, the velocity of the molten metal flow relative to the surface tension and the channel thickness. The data used in the mathematical model of the fluidity in thin section under vibration condition were deduced experimentally; namely, velocity of the molten metal and the heat transfer coefficient between the liquid metal and the chilled surface of the mould. This model was used to estimate the fluidity characteristics in thin wall investment casting with and without vibration. Real-time X-ray observation and computer modelling of the metal head-driven mould filling sequences reveal that no surface turbulence occurred when the liquid metal flowed into the thin section and the advance metal front continued to flow under surface tension control. X-ray was also used to measure the flow time and the velocity of the metal inside the thin channel and confirm the modification on Bernoullis Equation (kinetic energy+ potential energy = constant) to estimate the velocity relative to surface tension in the fluidity mathematical model. Flow-3D software was used to calculate the velocity of the liquid metal in the flowability filling type and the fluidity characteristics. Weibull analysis identifies the acceleration vibration as practical criterion to judge the reliability of casting. A vibration mould with vertical direction in the thin wall investment casting after filling can make the liquid metal flow into the thin section under surface tension control. This technique is used to achieve mould filling free from misrun defects and surface turbulence and this makes vibration casting a promising technique for producing high quality castings. On the basis of these findings, an operation window for the production of reliable castings has for the first time been developed in this research.

No description available.

A high γ' volume fraction Ni-base superalloy (RR1000) has been studied and its microstructural and mechanical response to the inertia welding process assessed. The bond line microstructure has been characterised in terms of process parameters and associated modelled temperature distributions. The high temperature mechanical behaviour has been interrogated via sustained load crack growth testing in air and vacuum. The weld microstructure is characterised by a uni-modal distribution of ultrafine γ' and a meta-dynamically recrystallised grain structure. The recrystallised grain size is determined by the width of the shear zone and the associated deformation behaviour, which varies with process parameter selection. Of particular importance is the welding pressure, which controls the upset rate, thereby limiting the shear zone width. A restricted shear zone can be related to increases in the peak bond line temperature and cooling rate. The high temperature crack growth behaviour is controlled by grain boundary oxide formation and crack tip stress state. In inertia welded RR1000 this stress state is governed by the reprecipitated γ'. The steady state crack growth rate increases with temperature, which is due to an increased rate of oxide formation. Near threshold growth behaviour is also dependent on localised microstructural features.

The adoption of lithium-ion and/or super-capacitor battery technologies is a current hot topic in the automotive industry. For both battery types, the terminals and busbars are manufactured from copper (Cu) and/or aluminium-based (Al-based) alloys, as a result of their high electrical and thermal conductivities. Laser welding is considered an attractive process to industry due to its easy auto-motability, high processing speed and highly repeatable cost-effective processing. However, laser welding of monometallic and dissimilar Cu and A1 presents several difficulties due to the high surface reflectivity at infrared (IR.) wavelengths. Three main areas were investigated in this research work: • Laser beam lap-welding of monometallic Cu sheets, with the aim of validating the developed welding procedures against target specifications addressed by the automotive industry, in line with production environment setups. • The suitability of using tailored energy distributions, produced using a 1070nm laser source delivered through a laser beam scanner, for welding multiple overlapping Al or Cu foils. • The effects of different laser processing parameters on the formation of deleterious brittle intermetallic phases when welding Alto Cu with a continuous-wave Yb-fibre laser.

Linear friction welding (LFW) is a solid-state welding process (i.e. the melting temperature of the material is not reached) that is used for the fabrication of titanium alloy bladed discs (Blisks) in the fan and compressor stage of modern aero engines. Blisk technology enables a 20-30 % weight saving through removing the need for the dovetail attachment thus enabling slimmer, lighter and more streamlined disc architecture. This significant weight saving helps the aero engine meet environmental targets (ACARE, 2000) by reducing fuel burn, noise and emissions as well as eliminating fretting fatigue around the dovetail attachment and extending component life. LFW is considered to be a self-cleaning process where contaminants trapped within the plasticised layer are expelled into the flash thus producing a high integrity weld that is stronger than the parent material. This high integrity is critical for Blisk application as contaminants in the final weld joint may result in reduced component life or sudden unexpected failure. Despite the importance of weld integrity for Blisk applications, little is known about the underlying process physics of the cleaning regime therefore the aim of this thesis is to provide a thorough mechanistic understanding of the weld evolution of Ti- 6Al-4V LFW by empirically evaluating weld efficiency, material flow behaviour and weld cleaning behaviour over a range of appropriate key process variables.

An evaluation of inertia friction welds in RR1000 has been conducted through microtensile and sustained load crack growth tests on pre-cracked testpieces. As-welded and two post weld heat treatment conditions have been considered. The fatigue crack growth behaviour of γ TiAl has also been considered, with a focus on establishing fatigue crack growth thresholds.

In this work, a portfolio of novel active screen plasma surface engineering technologies have been developed including active screen plasma surface modification of carbon paper for gas diffusion layer (GDL) and active screen plasma surface co-alloying of 316 austenitic stainless steel with both interstitial alloying element of nitrogen and such substitutional alloying elements as silver (Ag), niobium (Nb) and platinum (Pt). The active screen plasma surface modification of GDL carbon paper at a low temperature for a short period of time can effective activate the carbon paper surface mainly due to the removal of the hydrophobic PTFE coating and introduction of many functional groups, thus contributing to the improved growth of Pt nano-wires. Accordingly, the electrochemical and catalysis performance can be effective improved. The novel ASP surface alloying technique developed from this research has been applied to modify the 316 stainless steel surface using nitrogen for active screen plasma nitriding (ASPN); nitrogen and silver (N&Ag); nitrogen and niobium (N&Nb); and nitrogen and platinum (N&Pt). The experimental results have demonstrated that the layer structure of the ASP treated 316 SS surfaces can be tailored by using different alloying elements and/or adjusting treatment parameters. The surface electrical conductivity of 316 can be reduced significantly. The ASPN, ASPA(N&Ag) and ASPA(N&Nb) increase the corrosion potential, lower the corrosion current density, but raise the passive current density of 316 SS. Among all the surface alloying treatments, the ASPA(N&Pt) treatment has delivered the best performance and fulfilled the technique target set by the Department of Energy (DoE), USA.

A comprehensive study of microstructure, texture and mechanical properties of Ti-6Al-4V joints produced by inertia friction welding is addressed in this thesis. Axis-symmetric tubular welds of different wall thicknesses were produced using different welding parameters. In the present study, there are two thin wall welds and three thick wall welds. A martensitic transformation occurred in the thin wall welds, resulting from the fast cooling rate, whereas it is prevented in the thick wall welds. The acicular microstructure in the Centre Weld Zone is finer and plastic deformation in the Thermal Mechanical Affected Zone is more severe with a higher energy input. In thick wall welds, prior β grain boundaries and grain boundary α are more clearly observed. Based on the reconstruction of prior β grains, the average β grain size can be related to the exponential of the forged pressure over the average input power density. The mechanical behaviour of both thin wall and thick wall welds for the varied welding parameters is also investigated, including tensile tests, fracture toughness tests, low cycle fatigue and fatigue crack growth resistance tests.

This thesis addresses aspects of the development of both processing methods and the assessment of the mechanical properties of titanium metal matrix composites in order for the material to be introduced with confidence into aero-engine applications. Assessment of the SM1140+ fibre has been carried out and compared with the SCS-6 and Trimarc fibres in order to gain an appreciation of the performance of these fibres in relation to each other to aid fibre selection and to aid further development of composite components. The SM1140+ fibre is found to fail almost always from the core and is consistent with a statistical distribution that can be modelled by a unimodal Weibull approach. The development of the SM2156 fibre was made in an effort to produce both a UK source and a lower cost source of fibre. Mechanical testing of fibre in both as-received and composite form revealed a decrease in strength when compared with results for the virgin, uncoated fibre and by deduction from SCS-6 composite mechanical behaviour. The deterioration of fibre properties appears to be caused by the rough surface of the SiC fibre causing a ‘keying’ effect that inhibits interfacial sliding. The high rate sputtering deposition process has been developed in order to obtain an alternative, lower cost method of producing matrix coated fibre. Testing of the MCF showed a mild deterioration of fibre strength during processing (due to fibre spooling), but still demonstrated the composite shows potential for production given further development.