The miniaturization of electronics packaging is an ongoing trend. The manufacturers are increasing the packaging density to accommodate for more complex designs and increase in operating frequencies. The surface mount devices (SMDs) and today's manufacturing processes are starting to become a limiting factor to this miniaturization. The solution to these problems are embedded passives and new fully-additive manufacturing processes. In this work, a planar inductor is fabricated using a fully-additive process called Sequential Build-Up - Covalent Bonded Metallization (SBU-CBM). A new grafting material for the CBM process is tested, but found to be worse than the previously used one when tested on FR4 substrates. The best design of a planar inductor for high inductance and high Q factor is found to be the circular spiral inductor. A planar circular spiral inductor with a feature size of 75 µm is successfully fabricated using the SBU-CBM process.

In manufacture of cement-bonded particle boards are in present-days used exclusively wooden particles as filler. This thesis deals with a research of possible substitution of this material, especially of waste emerging by production of CBPB itself. At first is completed a survey of possible substitute fillers and czech and foreign literature, dealing with issues of modification of composition of cement-bonded particle boards. In practical part are tested some treatments of waste and its adding to recipe. Further are analysed the influences of substitution of cement by slag and substitution of wooden particles by recycled fibreglass. By laboratory work with CBPB is monitored the influence of amounts of added wather to fresh mixture and also to properties of finished elements.

In this manuscript, distinct problems concerning carbon-bonded materials processing and characterization were analyzed, from bulk to cellular samples. The main motivation was to address central topics that would enhance the comprehension of the material’s behavior, as well as trigger targeted improvements. Some of the topics this thesis covers are: Non-linear Young’s modulus behavior of carbon-bonded alumina at high temperatures; Influence of the processing route on the cold crushing strength of carbon-bonded alumina foam filters; Geometric characterization of ceramic foam filters as a tool to understand processing parameters; Use of advanced techniques such as computer tomography and finite element modelling to correlate processing parameters and mechanical behavior. In most of the analyses, non-standard computational strategies were adopted. In those cases, algorithms were written to facilitate the evaluations, or even enable it in the first place. All the algorithms’ concepts are described in this thesis and their codes are available in the Appendices. The current work was carried out within the framework of the Collaborative Research Center 920 (CRC 920) “Multifunctional filters for metal melt filtration - a contribution to zero defect materials” at the Technische Universität Bergakademie Freiberg funded by the German Research Foundation (DFG).

Increasing ecological and economic pressures, as well as increased technical requirements, have given rise to the need for research into alternative wear layers for hydrodynamic plain bearings. Previous investigations have tested and researched the bonded coating GL92. It has been possible to demonstrate that the bonded coating (plastic base) is a viable alternative to a conventional white metal alloy. However, this coating was not able to address all the issues experienced by industrial users, for example the behaviour of the system (changes to operating properties) during penetration of particles, or behaviour in a mixed friction area. The literature has not – or not sufficiently – answered the questions relating to damage patterns and damage tolerance. Therefore, regardless of the proven benefits, industrial use of this coating is currently not possible or is connected with significant risks. In the study, tests were carried out in the mixed friction area (start-stop testing, emergency testing without oil, insufficient lubrication tests) as well as in the hydrodynamic area. The comparative tests were performed on different wear layer materials. This paper demonstrates and discusses the results for both a conventional white metal alloy bearing and for the bearing with bonded coating (GL92). Depending on the operating point, the bearing systems exhibit significant differences at the maximum bearing load, lubricating film pressure distribution and maximum bearing temperature. The investigation has proven that GL92 is a technically useful alternative to conventional wear layers.

Thermal shock resistance is a key property of refractory materials. Its determination and prediction is essential for the design of structural refractories as well as lining materials. Young’s modulus of elasticity (E) is a crucial parameter for the calculation of thermal shock resistance. For all investigated carbon-bonded alumina composition a significant increase of E was observed. This increase was attributed to a mismatch of the coefficient of thermal expansion of the composite constituents. Besides others, the graphite content as well as the maximum alumina particle size were identified as crucial factors influencing E(T). Furthermore, the influence of the porosity on E was shown and existing models were fitted to the experimental data for future predictions of E. Finally a metal melt filter structure was investigated to investigate the relationship between its strut Young’s modulus and the structures’ E at high temperatures. Further research should address the filter topic since it was uncertain how to find the normal modes of those structures.

Mit multiaxialen Gelegen auf Basis der Kettenwirktechnik stehen hervorragende textile Halbzeuge für die Weiterverarbeitung als Verstärkungskomponente in Faser-Kunststoff-Verbunden zur Verfügung. Die bisherige Konfiguration der für die Herstellung dieser Textilien verwendeten Nähwirkmaschinen führt verfahrensbedingt zu einem unsymmetrischen Produktaufbau mit üblicherweise nur einer Fadenlage in Gelegelängsrichtung und ebenso zu Einschränkungen bei der Anordnung des Bindefadens im Textil. Durch die Erweiterung des Nähwirkprozesses wird es möglich, Nähwirkstoffe mit einer beliebigen Abfolge der Einzellagen herzustellen, zum Beispiel in symmetrischer Anordnung. Die neuen Varianten der Lagenanordnung und der Bindungskonstruktion bilden den Ausgangspunkt für die Produktentwicklung am Beispiel zweier Anwendungen aus den Bereichen der Faser-Kunststoff-Verbunde und des textilbewehrten Betons. Hier wird deutlich, dass über die Herstellung symmetrischer Gelege hinaus der Einsatz des erweiterten Wirkprozesses die Eigenschaften der Gelege und der Endprodukte vorteilhaft beeinflussen kann. Aus den untersuchten Beispielen und grundsätzlichen Betrachtungen leitet sich ab, unter welchen maschinentechnischen Voraussetzungen der Einsatz des erweiterten Wirkprozesses sinnvoll ist. Es wird ein Konzept entwickelt, auf dessen Grundlage Nähwirkstoffe mit variabler Lagenanordnung auf Nähwirkmaschinen gefertigt werden können. / Multiaxial multi-ply fabrics made by warp knitting are excellently suited for the application in fiber reinforced composites. The usual configuration of the stitch-bonding machines, which are used to produce these fabrics, necessarily leads to composite laminates with an asymmetric layer arrangement and only one layer of yarns in the zero degree direction of the fabric. The variability of patterning with the binding yarn is also limited. By completing the stitch-bonding process with an additional work step it is possible to produce stitch-bonded fabrics without any restrictions concerning the arrangement of the individual layers in the fabric, for example with a symmetric composition. This is the basis for the development of two exemplary products in the fields of textile reinforced plastics and textile reinforced concrete. It can be shown that the application of the extended stitch-bonding process is advantageous beyond the layer arrangement, positively affecting the mechanical properties of the fabric and the composite. From these examples, conclusions are drawn regarding the configuration of future stitch-bonding machines.

<div> <p>Due to harsh environmental conditions, the deterioration of prestressed concrete bridge girders is a commonly observed phenomenon in Indiana and much of the Midwest. Concordantly, one widely observed damage scenario is deteriorated end regions of prestressed concrete girders. Damaged or failed expansion joints expose prestressed concrete girder end regions to chloride-laden water, resulting in a corrosive environment in which reinforcement section loss and concrete spalling can occur. For bridges experiencing this type of deterioration, action is needed to ensure the structure remains safe and serviceable. As such, an experimental program was developed to investigate the effectiveness of three repair techniques in restoring the structural behavior of prestressed concrete bridge girders with end region deterioration. The three examined repair techniques are (i) an externally bonded fiber reinforced polymer (FRP) system, (ii) a near-surface-mounted (NSM) FRP system, and (iii) a concrete supplemental diaphragm. Additionally, installation procedures for the three end region repair techniques were developed. Results, conclusions, and recommendations from the experimental program are presented to help advise best practices for implementing end region repair techniques in the field. </p> </div> <br>

<p>If designed and constructed properly, post-tensioned construction can provide improved durability and offers the ability to construct longer span bridges and curved girders. Furthermore, this method of construction has become economically competitive with traditional, pretensioned concrete and steel plate girder bridges. A critical issue, however, has been corrosion of the steel strand. While grouting has been the primary corrosion protection method for the strand, experience has shown that grouting presents its own problems and limitations that compromised the durability and service-life of bridges. As a result, unbonded post-tensioning has gained interest as it eliminates issues with grouting and allows for inspection as well as future strand replacement. The behavior and strength of structures constructed with unbonded post-tensioning, however, is not well understood, especially shear strength. Therefore, the objective of this research investigation is to evaluate the structural performance of prestressed girders containing unbonded tendons with a primary focus on shear strength. The scope of this phase of the research was to develop the means and methods to construct and test girder specimens with multiple design criteria and allow evaluation of multiple test variables. The research developed the materials and procedures to enable the large scale testing program to be developed. Finally, the procedures developed were verified through the construction of the initial set of test specimens and testing of the first shear specimen.</p>

<p>  </p> <p>Polymer bonded explosives (PBX) are a particle reinforced composite containing a high solids loading of explosive particulates bound in a polymer matrix. Commercially produced energetic particulates contain some percentage of flaws in the form of contaminants, porosity, and preexisting fractures. Additional large-scale porosity within the composite is generated during PBX formulation. The introduction of novel additive manufacturing techniques to the energetics field alters the known composite structure and introduces a porosity variable that has not been fully characterized. Porosity collapse during deformation is believed to be a predominant mechanism for hotspot formation, which dominates shock initiation behaviors. These phenomena are difficult to experimentally characterize due to inherent small spectral and temporal scales, and as such numerical and computational models are relied upon to inform fundamental physics. Experimental characterization of the behaviors of energetic materials during deformation is necessary to better inform computational studies and improve our understanding of hotspot formation mechanisms. </p> <p>This dissertation experimentally evaluates the high-rate deformation of porosity in individual explosive particulates and within the overall composite structure. This has included the development of a novel micromachining technique for pore generation in energetic single crystals using the focused ion beam (FIB), resulting in precise and controllable porosity generation that is easily reproducible in collaboration with computational studies. FIB was shown to be an effective pore generation technique, verified by assessing surface roughness and pore quality compared to contemporary manufacturing methods. Three experimental subsets are evaluated: surface cracks in HMX single crystals, polygonal pores in HMX single crystals, and large-scale porosity variations in mock vibration assisted print (VAP) produced composites of borosilicate glass beads and Sylgard 184® binder. A single stage light gas gun was used to impact the samples at 400 m/s and the impact event and resultant material response were observed in real time using x-ray phase contrast imaging (PCI). Machined surface cracks were shown to have negligible effect on the final fracture behaviors of HMX crystals. In polygonal pores fractures were shown to originate due to stress concentration during impact followed by otherwise expected brittle fracture behaviors. For wedge-like pores, the shockwave culminates on the front face of the pore and contributed to early fracture in some samples as well as a consistent open fracture opposite the impact along the shockwave direction in later stages of impact. For the blunt rectangular-like pores two differing behaviors were observed, wherein either the pore condensed and fracture at the pore was not seen during the impact event or large open fractures formed at the pore corners opposite the shockwave. The variance in response is attributed to the energy of fracture dissipating somewhere else in the material bulk, like the behaviors observed in the milled slot samples. Finally, additively manufactured PBX deformation behaviors were observed to be dominated by the collapse of the existing ordered porosity in the bulk which occurred at an increased rate relative to the bulk material compression. This resulted in a three-stage progression of deformation, consisting of a rapid collapse of large-scale ordered porosity, followed by the densification of the remaining features, and ultimately ending in compaction of the bulk as the impact projectile fully compressed the samples. Future work includes exploration of further FIB produced pore effects on dynamic fractures, evaluation of printed material deformation behaviors at additional rates, as well as application and evaluation of additional VAP printed material formulations.  </p>

[pt] Desenvolveu-se estudo teórico e numérico para simular o comportamento tensão-deformação de solos e rochas. Procurou-se estabelecer modelagem constitutiva apta a representar as peculiaridades inerentes ao comportamento destes materiais sob grandes deformações e degradação da estrutura. Dentro do contexto geotécnico brasileiro, o objetivo da pesquisa foi, também, investigar uma nova abordagem constitutiva para modelar o comportamento de solos moles, solos residuais e rochas sedimentares. O trabalho está dividido nos seguintes tópicos: revisão bibliográfica; estudo de medidas de deformações e taxas objetivas de tensões; definição e desenvolvimento dos modelos constitutivos a serem testados; definição dos algoritmos de retorno para integração das equações constitutivas; implementação em elementos finitos; simulação do comportamento observado em ensaios de laboratório. Os resultados da pesquisa indicam que o comportamento viscoso da argila mole do Sarapuí pode ser reproduzido corretamente adotando-se modelo constitutivo viscoplástico. A abordagem de solo estruturado está condizente com o comportamento do arenito de Vila Velha. Por fim, para modelar o comportamento de solos residuais dentro de um novo quadro constitutivo, foi proposta uma separação das deformações irreversíveis. / [en] A theoretical and numerical study was developed to simulate the stressstrain behavior of soils and rocks, formulating constitutive models able to catch the peculiarities inherent to the behavior of these materials under large strains and structure degradation. Within the Brazilian geotechnical context, the objective of the research was also to investigate constitutive approaches to model the behavior of soft soils, residual soils and sedimentary rocks. The work is divided into the following topics: literature review; study of strain measurements and objective stress rates; definition and development of the constitutive models to be tested; definition of the return mapping algorithms for integrating the constitutive equations; finite element implementation; and simulation of the behavior observed in laboratory tests. Results indicate that the viscous behavior of the Sarapuí soft clay can be correctly reproduced by adopting a viscoplastic constitutive model. The structured soil approach appears to be consistent with the behavior of Vila Velha sandstone. Finally, a decomposition of irreversible strains was proposed to model the behavior of residual soils within a novel constitutive framework.