The unique thermo-mechanical behavior of Shape Memory Alloys (SMAs), such as their ability to recover the original shape upon heating or being able to tolerate large deformations without undergoing plastic transformations, makes them a good choice for actuators. This work studies their application in the aerospace and defense industries where SMA components can serve as release mechanisms for gates of enclosures that have to be deployed remotely. This work provides a novel approach in evaluating the stress and heat induced change of phase in a SMA, in terms of the transformation strain tensor. In particular, the FEA tool ANSYS has been used to perform a 2-D analysis of a Cu-Al-Zn-Mn SMA specimen undergoing a nontraditional loading path in two steps with stress and heating loads. In the first load step, tensile displacement is applied, followed by the second load step in which the specimen is heated while the end displacements are held constant. A number of geometric configurations are examined under the two step loading path. Strain results are used to calculate transformation strain which provides a quantitative measure of phase at a material point; when transformation strain is zero, the material point is either twinned martensite, or austenite depending on the temperature. Transformation strain value of unity corresponds to detwinned martensite. A value between zero and one indicates mixed phase. In this study, through two step loading in conjunction with transformation strain calculations, a method for mapping transient non-uniform distribution of phases in an SMA is introduced. Ability to obtain drastically different phase distributions under same loading path by modifying the geometry is demonstrated. The failure behavior of SMAs can be designed such that the load level the crack initiates and the path it propagates can be customized.

Understanding how different processing variables influence wood welded bonds is vital if the technique will ever be used to create engineered lumber without using adhesives. A variation of vibration welding, wood welding uses pressure and friction to bond materials together. During welding, heat causes a softening in the wood, a naturally occurring composite material. This softening leads to fiber entanglement and a bond forms upon cooling. The goal of this research was to investigate several processing aspects of the wood welding procedure. A prototype wood welding machine, designed and fabricated from the ground up, was used to investigate the effects of various welding parameters using birch wood. Wood welds were evaluated on the basis of bond coverage and ultimate shear strength. Four experiments were performed: welding frequency and duration interaction, grain orientation effects, alternative welding completion metrics, and strength development over time. During the wood welding process, three distinct phenomena were repeatedly observed: smoke creation, welding residue formation, and an audible pitch change. The presence of each was recorded for every wood welded specimen and used later in additional data analysis. Investigating each of the welding phenomena was done in an attempt to better characterize when fusion was achieved at the weld interface. ImageTool, an image analysis software package, was used to investigate and quantify the often irregular bonds exposed after shear fracture. The results of the various welding variables were analyzed on the basis of shear strength and bond uniformity. From the birch samples, it was shown that better bonds result from lower welding frequencies and longer welding durations. The grain orientation analysis demonstrated that welding orientation marginally affects the average shear strength of the wood weld. The data from the alternative welding metrics suggests that welding time is not a quality indicator of welding completion (bond coverage). The strength development trials confirmed previous research; wood welds obtain most of their strength in a relatively short period of time. Douglas fir and poplar both proved to be weldable for the first time, but they were sufficiently weaker than birch. When welding was attempted with Douglas fir under similar pressures used for birch, Douglas fir samples would commonly “washboard.” With reduced welding pressure, Douglas fir formed wood welds more easily.

Due to their ability to confer enhanced surface properties without compromising the properties of the substrate, coatings have become ubiquitous in heavy industrial applications for corrosion, wear, and thermal protection, among others. Kinetic Metallization (KM), a solid-state impact consolidation and coating process, is well-suited for depositing industrial coatings due to its versatility, low substrate heat input, and low cost. The ability of KM coatings to adhere to the substrate is determined by the quality of the interface. The purpose of this study is to develop a model to predict the interfacial quality of KM coatings using known coating and substrate properties. Of the various contributions to adhesion of KM coatings, research suggests that the thermodynamic Work of Adhesion (WAD) is the most fundamental. It is useful to define interfacial quality in terms of the critical strain energy release rate (GC) at which coating delamination occurs. Studies show that GC for a given interface is related to WAD. This study attempts to develop a theoretical model for calculating WAD and understand the relationship between GC and WAD. For a bimetallic interface between two transition metals, WAD can be theoretically calculated using known electronic and physical properties of each metal: the molar volume, V, the surface energy, γ, and the enthalpy of alloy formation, ΔHinterface; ΔHinterface is a function of the molar volume, V, the work function, φ, and the electron density at the boundary of the Wigner-Seitz cell, nWS.WAD for Ni-Cu and Ni-Ti interfaces were 3.51 J/m2 and 4.55 J/m2, respectively. A modified Four-point bend testing technique was used to experimentally measure GC for Ni-Cu and Ni-Ti specimens produced by KM. These tests yielded mean G­C values of 50.92 J/m2 and 132.68 J/m2 for Ni-Cu and Ni-Ti specimens, respectively. Plastic deformation and surface roughness are likely the main reasons for the large discrepancy between GC and WAD. At the 95% confidence level, the mean GC of the Ni-Ti interface is significantly higher than that of the Ni-Cu interface. Further testing is recommended to better understand the relationship between WAD and GC.

Material thermal properties are highly sought after to better understand the performance of a material under particular conditions. As new materials are created, their physical properties will determine their performance for various applications. These properties have been estimated using many techniques including experimental testing, numerical modeling, and a combination of both. Existing methods can be time consuming, thus, a time-efficient and precise method to estimate these thermal properties was desired. A one-dimensional finite difference numerical model was developed to replicate the heat transfer through an experimental apparatus. A combination of this numerical model and the Continuous Genetic Algorithm optimization technique was used to estimate material thermal properties of fibrous insulation from test data. The focus of this work was to predict these material thermal properties for an Alumina Paper that is commonly used in aerospace applications. The background, methodology, and results are discussed.

The yttria-stabilized zirconia (YSZ) system has been extensively studied because of its critical applications, like solid oxide fuel cells (SOFCs), oxygen sensors, and jet engines. However, there are still important questions that need to be answered and significant thermodynamic information that needs to be provided for this system. There is no predictive tool for the ionic conductivity of the cubic-YSZ (c-YSZ), as an electrolyte in SOFCs. In addition, no quantitative diagram is available regarding the oxygen ion mobility in c-YSZ, which is highly effective on its ionic conductivity. Moreover, there is no applicable phase stability diagram for the nano-YSZ, which is applied in oxygen sensors. Phase diagrams are critical tools to design new applications of materials. Furthermore, even after extensive studies on the thermodynamic database of the YSZ system, the zirconia-rich side of the system shows considerable uncertainties regarding the phase equilibria, which can make the application designs unreliable. During this dissertation, the CALPHAD (CALculation of PHase Diagrams) approach was applied to provide a predictive diagram for the ionic conductivity of the c-YSZ system. The oxygen ion mobility, activation energy, and pre-exponential factor were also predicted. In addition, the CALPHAD approach was utilized to predict the Gibbs energy of bulk YSZ at different temperatures. The surface energy of each polymorph was then added to the predicted Gibbs energy of bulk YSZ to obtain the total Gibbs energy of nano-YSZ. Therefore, a 3-D phase stability diagram for the nano-YSZ system was provided, by which the stability range of each polymorph versus temperature and particle size are presented. Re-assessment of the thermodynamic database of the YSZ system was done by applying the CALPHAD approach. All of the available thermochemical and phase equilibria data were evaluated carefully and the most reliable ones were selected for the Gibbs energy optimization process. The results calculated by the optimized thermodynamic database showed good agreement with the selected experimental data, particularly on the zirconia-rich side of the system.

<p>A new NO_x sensor for high-temperature applications has been developed and thouroghly characterised. The sensor layers are a mixed oxide of CoO, MgO and MgO₂ deposited by thermal evaporation with a porous platinum gate on top, deposited by thermal evaporation or sputtering. The sensitivity and selectivity of the sensor is promising and is shown to depend upon the ratio between Co and Mg in the film and a number of competing mechanisms are shown to take place on the sensor surface. Response and recovery of the device is still slow and there are some drift, which are suggested to be due to a restructuring sensor surface during operation that was found by SEM-studies. Finally,the oxide surface has been characterized by XPS and a novel process for deposition of the sensor layers by lift-off technique has been developed.</p>

Instrumented nanoindentation techniques have been widely used in characterizing mechanical behavior of materials in small length scales. For defect-free single crystals under nanoindentation, the onset of elastic-plastic transition is often shown by a sudden displacement burst in the measured load-displacement curve. It is believed to result from the homogeneous dislocation nucleation because the maximum shear stress at the pop-in load approaches the theoretical strength of the material and because statistical measurements agree with a thermally activated process of homogeneous dislocation nucleation. For single crystals with defects, the pop-in is believed to result from the sudden motion of pre-existing dislocations or heterogeneous dislocation nucleation. If the sample is prestrained before nanoindentation tests, a monotonic decrease of the measured pop-in load with respect to the increase of prestrain on Ni and Mo single crystals is observed. A similar trend is also observed that the pop-in load will gradually decrease if the size of indenter tip radius increases. This dissertation presents a systematic modeling endeavor of energetics and kinetics of defect initiation in the stressed volume at small scales. For homogeneous dislocation nucleation, an indentation Schmid factor is determined as the ratio of maximum resolved shear stress to the maximum contact pressure. The orientation-depended nanoindentation pop-in loads are predicted based on the indentation Schmid factor, theoretical strength of the material, indenter radius, and the effective indentation modulus. A good agreement has been reached when comparing the experimental data of nanoindentation tests on NiAl, Mo, and Ni, with different loading orientations to theoretical predictions. Statistical measurements generally confirm the thermal activation model of homogeneous dislocation nucleation, because the extracted dependence of activation energy on resolved shear stress is almost unique for all the indentation directions. For pop-in due to pre-existing defects, the pop-in load is predicted to be dependent on the defect density and the critical strength for heterogeneous dislocation nucleation. The cumulative probability of pop-in loads contains convoluted information from the homogenous dislocation nucleation, which is sensitive to temperature and loading rate, and heterogeneous dislocation nucleation due to the unstable change of existing defect network, which is sensitive to the initial defect distribution.

Fusion energy has been said to be the solution to all the world’s energy problems. The International Thermonuclear Experimental Reactor (ITER) is the flagship project to demonstrate the feasibility of fusion energy. The Central Solenoid (CS), an important component of the reactor, is needed to induce plasma current, initiate, ramp-up, ramp-down, and sustain plasma in a very controlled manner. In order to achieve this, the CS coil packs must be manufactured under controlled conditions. The CS conductor is an advanced cable-in-conduit Nb3Sn superconductor. The CS cable will be made in long continuous sections but with thousands of meter of cable needed, splices will have to be made in the field during construction of the ITER reactor. With the ends of the CS cable being exposed to the environment for an unspecified amount of time, concern has been expressed about the effect of the cable exposure on the quality of the splice. As a result an experimental program was devised to replicate and expedite the environmental damage the cable may see while in the field. The CS cable samples were exposed to 100% humidity at 60, 80, and 100oC for periods ranging from one week to four weeks. Once the samples were soaked for a period of time they were then sintered as would be done in the field. After sintering the mechanical tests were done to determine the load required to push the sintered strands out of the copper sleeve. Initial results obtained with samples having the sleeve thickness of 1.25mm (0.05in) were inconclusive due to the presence of a fold in the copper sleeve formed during the compaction of the sleeve around the cable. To prevent the fold formation, another set of samples were prepared with thicker copper sleeve of 5mm (0.20in). Results from these samples yielded data that was more conclusive and showed a possible correlation between aging temperature and sintering strength. The experimental data suggests that the thin oxide layer formed during the elevated temperature soak at 100% humidity may even be beneficial to the sinter quality.

Theoretical studies of point defect interactions and structural stability of compounds have been performed using density functional theory. The defect-related properties, such as activation energy of diffusion, electronic and magnetic structure of selected materials have been studied. The major part of the present work is devoted to a very important material for semiconductor industry, GaAs. The formation energies of intrinsic point defects and the solution energies of 3d transitions in GaAs have been calculated from first principles. Based on the calculated energies, we analysed the site preference of defects in the crystal. The tendency of defects to form clusters has been investigated for the intrinsic defects as well as for impurities in GaAs. The magnetic moment of 3d impurities has been calculated as a function of the chemical environment. The possibility of increasing the Curie temperature in (Ga,Mn)As by co-doping it with Cr impurities has been examined on the basis of calculated total energy difference between the disordered local moment and the ferromagnetically ordered spin configurations. We found that, in order to reach the highest critical temperature, GaAs should be separately doped with either Cr or Mn impurities. Also, we have shown that diffusion barrier of interstitial Mn depends on the charge state of this impurity in (Ga, Mn)As. The formation of defect complexes between interstitial and substitutional Mn atoms, and their influence on the value of diffusion barrier for interstitial Mn, has been studied. The pair interactions energies between interstitial oxygen atoms in hcp Zr, Hf and Ti have been calculated using first principles. Based on the calculated energies, the oxygen ordering structures in IVB transition metal solid solutions have been explained. A prediction of nitrogen ordering in Hf-N solid solution has been made. The thermodynamic description of intermetallic compounds in the Zr-Sn binary system has been obtained. The conclusion has been made that Zr substitution on the Sn sites takes place in the Zr4Sn phase, which accounts for the unusual stoichiometry of this Cr3Si structure type compound. The influence of pressure on the phase stability in the Fe-Si system has been investigated. We have found instability of the hcp Fe0.9Si0.1 random alloy with respect to the decomposition onto the Si-poor hcp Fe alloy and the B2 FeSi under high pressure. The tendency of this decomposition becomes stronger with increasing the applied pressure. / QC 20100624

Experiments on the production of porous metallic materials were performed on Fe-base and Al-base alloys. The method involves dissolution of gases in the liquid state and solidification at various cooling rates. The alloy compositions were selected to induce solidification of primary particles intended to control the pore distribution. For the Fe-base alloys, nitrogen was introduced into the melt by dissolution of chromium nitride powder. Fe-Cr-Mn-Si-C alloys featuring M7C3 carbide particles were selected. For the Al-base alloys, hydrogen gas was dissolved into the melt by decomposition of water vapor. Al-Ti and Al-Fe alloys featuring primary Al3Ti and Al3Fe intermetallic particles, respectively, were considered. In the Fe-base alloys, a homogeneous distribution of gas pores through the specimens’ volume was obtained at high cooling rate (water quenching) and after introduction of external nucleating agents. In the case of the Al-base alloys, a good pore distribution was observed at all cooling rates and without addition of nucleating agents. Calculations of the variation of nitrogen (respectively hydrogen) solubility based on Wagner interaction parameters suggest that pore nucleation and growth occur during precipitation of the primary particles (M7C3 carbides, Al3Ti or Al3Fe intermetallics), due to composition changes in the melt and resultant supersaturation with gas atoms. Microscopic analyses revealed that the primary particles control the pore growth in the melt and act as barriers between adjacent pores, thereby preventing pore coalescence and promoting a fine pore distribution. Uniaxial compression testing of the porous Al-Ti and Al-Fe materials showed the typical compressive behavior of cellular metals. Further work is needed to improve the quality and reproducibility of the porous structures which can possibly be used in energy absorption or load-bearing applications. As a corollary result of the quenching of hypereutectic Fe-Cr-Mn-Si-C alloys in the experiments of synthesis of porous metals, a homogeneous featureless structure was observed in some parts of the samples, instead of the equilibrium structure of M7C3 and eutectic phases. Subsequent investigations on rapid solidification of Fe-base alloys at various alloy compositions and cooling rates led to the formation of a single-phase structure for the composition Fe-8Cr-6Mn-5Mo-5Si-3.2C (wt.%), at relatively low cooling rates (≈103 K/s) and for large sample dimensions (2.85 mm). The single phase, which is likely to be the hcp ɛ-phase, was found to decompose into a finely distributed structure of bainite and carbides at ≈600 °C. The annealed structure showed very high hardness values (850 to 1200 HV), which could be exploited in the development of high-strength Fe-base materials. / QC 20100809