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Made available in DSpace on 2016-03-15T19:36:54Z (GMT). No. of bitstreams: 1 Maria Claudia Lopes Guerra.pdf: 9968717 bytes, checksum: 7d0e4986884ffa382a835b641ed76573 (MD5) Previous issue date: 2015-06-12 / Fundo Mackenzie de Pesquisa / The ECAP (Equal Channel Angular Pressing) is a mechanical process of Severe Plastic Deformation (SPD) where a sample is subjected to a shearing force when passing through the region of intersection of two channels. The main goal of this method is Severe Plastic Deformation achieve a microstructure with ultrafine grains, which have much higher than the equivalent coarse grain materials physical properties, such as an increase in strength and toughness simultaneously. What makes this increasingly interesting technique is that as there is no reduction cross section is possible to obtain plastic strain accumulation and therefore gain in grain order of nanometer scale. The great advantage of ECAP is to achieve a much higher degree of strain hardening than obtained by conventional methods of plastic deformation, and consequently a grain refining much higher as well. The importance of the study of severe plastic deformation process is on improving the mechanical performance of the materials and the possibility of a better understanding of the mechanisms of strain hardening, which may indicate a new path for producing high-strength materials, possibly scaled industrial. In this work are presented the microstructural, mechanical and electrical analysis of the aluminum alloy AA 1050 samples, commonly used for electrical purposes, with ultrafine grains (typical grain size below a micron) resulting from processing by ECAP, based on the method of SPD. / A PCE (Prensagem em Canais Equiangulares) consiste num processo mecânico de Deformação Plástica Intensa (DPI) onde um corpo de prova é sujeito a um esforço de cisalhamento ao passar pela região de intersecção de dois canais. Os principais objetivos desse método de Deformação Plástica Intensa é alcançar uma microestrutura com grãos ultrafinos, os quais possuem propriedades físicas muito superiores aos equivalentes materiais de grãos grosseiros, como um aumento em resistência mecânica e tenacidade simultâneas. O que torna esta técnica cada vez mais interessante é que como não há redução da seção transversal é possível obter acumulo de deformação plástica e com isso obter grãos na ordem de escala nanométrica. A grande vantagem do PCE é alcançar um grau de encruamento muito superior do que obtido por métodos convencionais de deformação plástica, e consequentemente, um refino de grão muito superior também. A importância do estudo do processo de deformação plástica intensa está na melhoria do desempenho mecânico dos materiais e na possibilidade de uma melhor compreensão dos mecanismos de encruamento, fato que pode indicar um novo caminho para a produção de materiais de alta resistência mecânica, possivelmente em escala industrial. Nesse trabalho são apresentadas as análises microestruturais, mecânicas e elétricas de amostras de ligas de alumínio AA 1050, comumente utilizadas para fins elétricos, com estrutura de grãos ultrafinos (tamanho de grão típico abaixo de um micrometro) resultantes do processamento por PCE, baseada no método de DPI.

This thesis is focused on design of the turbine housing CAD model applicable for mixed flow turbine. It also deals with strength analysis of designed turbine housing. The aim of the thesis is to create a three-dimensional turbine housing model accompanied by drawings.

Les polymères semi-cristallins sont des matériaux très répandus dans notre vie quotidienne et sont utilisés dans une large gamme d'applications, généralement sous des sollicitations viscoélastiques. Par conséquent, nombreux sont les travaux de recherche qui ont été menés ces dernières années afin d’étudier leurs propriétés élastiques et leurs micro-mécanismes de plasticité ou d'endommagement apparaissant en leur sein à l'échelle locale . Cependant, l'observation in situ de l'amorçage de ces mécanismes demeure problématique et requiert l’emploi d’équipements complexes. Dès lors, nous proposons d’utiliser des techniques d'analyse non destructives fondées sur la détection et la propagation d'ondes ultrasonores (US) afin d’obtenir de nouvelles informations sur l'initiation de la plasticité et de l'endommagement de polymères semi-cristallins. Plus précisément, nous avons utilisé les techniques de contrôle par ondes US et émission acoustique (EA) afin de caractériser la plasticité et l'endommagement de plusieurs PE , d’un PP et d’un PVDF lors d'essais de traction uniaxiale. La technique de contrôle US a permis de montrer que l'atténuation US de différents types d'ondes est élevée et augmente lorsque le taux de cristallinité du matériau diminue. Pour les ondes guidées, nous avons montré l'influence de la géométrie des éprouvettes ainsi que celle de la fréquence des ondes sur l'atténuation. Lors d’un essai de traction, une importante modification des paramètres US est observée lors du passage dans le domaine plastique, traduisant l'évolution de l'état de la microstructure, en particulier celui du réseau cristallin. La formation de micro-cavités a un impact significatif sur l'atténuation des ondes. L'effet de l'orientation des chaînes macromoléculaires a également été mis en évidence. L'activité acoustique des matériaux étudiés est faible mais il a été possible de vérifier que la majorité des signaux d'EA détectés proviennent bien des micro-mécanismes de plasticité et d'endommagement. L'effet de la vitesse de déformation est significatif et nous avons montré que la localisation de certains signaux est possible lorsque cette vitesse de déformation est élevée. L'activité acoustique présente trois phases au cours des essais de traction, ce qui nous a permis de proposer en conséquence un modèle de répartition des sources d'EA sur les éprouvettes. L'activité acoustique démarre toujours avant le seuil de plasticité montrant ainsi que des micro-mécanismes de plasticité et d'endommagement s'initient aux faibles déformations. La détection de signaux d'EA avant le seuil de plasticité dépend aussi du taux de cristallinité. Le nombre de signaux d'EA détectés ainsi que leur énergie augmentent avec le taux de cristallinité du matériau. Un critère de plasticité a donc été proposé. / Semi-crystalline polymers are widely used materials in our everyday life and in a large range of applications, generally under visco-elastic solicitations. Consequently, many of the recent years researches study their elastic properties and their plasticity or damage micro-mechanisms occurring at a local scale (nano and micrometer). However, in situ observations of the initiation of these mechanisms (e.g. shear crystallites, cavitation or martensitic transformation) remain problematic and require the use of complex devices. Therefore, we propose to use non-destructive evaluation techniques based on the detection and the propagation of ultrasonic (US) waves in order to obtain new information about the initiation of plastic deformation and damage of semi-crystalline polymers. More specifically, we have used US and acoustic emission (AE) techniques to characterize the plasticity and damage of several PE, a PP and a PVDF during tensile tests. The US monitoring technique showed that the US attenuation of several waves is high and increases when the degree of crystallinity of the material decreases. For guided waves, we showed the effect of the specimens’ geometry and the waves frequency on the US attenuation. A significant change of US parameters is observed at the elastic-plastic transition, reflecting changes in the microstructure’s state, in particular in the crystal network. The formation of micro-cavities has a significant impact on the attenuation. The effect of the orientation of macromolecular chains has also been highlighted. The acoustic activity of studied materials is weak but the majority of detected AE signals have been shown to actually originate from plasticity and damage micro-mechanisms. The effect of the strain rate is significant and we have shown that the localization of few signals is possible when the strain rate is high. The acoustic activity presents three phases during tensile tests, which allowed us to propose a model based on the distribution of AE sources on the specimens. The acoustic activity always starts before the yield point showing that plasticity and damage micro-mechanisms are initiated at small strains. The detection of AE signals before the yield point also depends on the crystallinity of the material. The number of AE signals and their energy increase with the degree of crystallinity. A plastic criterion has been proposed. The correlation between the acoustic signals and the different mechanisms is complex, however it seems that the cavitation, the breakage of crystalline lamellae and the martensitic transformation are responsible for the release of acoustic energy.

In order to understand and predict the fracture behaviour of polycrystalline materials from a fundamental perspective, it is important to first investigate plastic deformation at a crack tip in a ductile single crystal. In this context, it may be noted that when the crack opening displacement is much less than the grain size, the crack tip fields are entirely contained in a single grain. Further, some key structural components are being fabricated in single crystal form. For example, blades in high pressure turbines of jet engines are made of single crystals of Nickel-based superalloys. In view of the above considerations, a combined experimental and computational study of the crack tip stress and strain fields in FCC single crystal is carried out in the present work. The effect of constraint level, which is characterized by the T-stress under mode I, plane strain small scale yielding conditions, on the near-tip response is first analyzed for a crystal orientation in which the crack plane coincides with (010) and ¯the crack front lies along[101]direction. A family of finite element solutions are generated by employing a boundary layer approach within continuum crystal plasticity framework. The results show that the near-tip deformation field, especially the development of kink and slip shear bands, is sensitive to the constraint level. On imposition of negative T-stress, a significant drop in the hydrostatic stress level is noticed in the region ahead of the tip. This suggests loss of crack tip constraint with negative T-stress, which is akin to isotropic plastic solids. The reason for the loss of crack tip constraint is traced to the occurrence of an elastic sector near the notch tip. The results also show that a two-parameter (such as K-T or J-Q) characterization of near-tip fields is necessary to accommodate different constraint levels in FCC single crystals. The results of the boundary layer formulation are used to guide the construction of asymptotic solutions near the crack tip corresponding to various constraint levels in elastic-perfectly plastic FCC single crystal. Two families of alternate asymptotic solutions are constructed by introducing an elastic near-tip sector. These families of stress fields are parameterized by the normalized opening stress ahead of the tip, τA22/τo, where τo is the critical resolved shear stress, and a quantity (p) which characterizes the coordinates of the point where elastic unloading commences in stress plane. The results show that the stress distribution corresponding to each member of these families, as well as the trajectories in stress plane as the crack tip is traversed, agree well with finite element results for a certain value of T-stress. In order to validate the above numerical and analytical solutions, the nature of crack tip deformation in aluminium single crystals is examined experimentally in a high constraint three point bend (TPB) specimen and in a low constraint single edge notch tensile (SENT) geometry. These experiments provide evidence, based on in-situ Electron Back Scattered Diffraction (EBSD) of the existence of kink shear bands (involving lattice rotation) exactly as predicted by Rice [J.R. Rice, Mech. Mater. 6 (1987) 317] and the present finite element analysis. The experimental investigation of a low constraint SENT geometry is also supplemented by 3D finite element computations based on continuum crystal plasticity. These computational results enable assessment of 3D effects near the tip. Finally, the effects of different lattice orientations (especially ones for which the slip systems are not symmetric with respect to the notch line) on the near-tip fields are studied pertaining to various constraint levels. The results obtained for different orientations show that the near-tip deformation field is sensitive to the constraint level. The stress distribution and the size and shape of plastic zone near the notch tip are also strongly influenced by the level of T-stress. It is clearly established that ductile single crystal fracture geometries, would progressively lose stress triaxiality with increase in negative T-stress irrespective of lattice orientation. Also, the near-tip field is shown to be part of a family which can be characterized by two parameters (such as K – T or J - Q).

Industrial products of high-strength Al-alloys are currently manufactured by thermo-mechanical processes, which are only applicable in the integrated plants requiring high investment cost. Moreover, reduction of the average grain size not less than 10 &mu / m and re-adjustment of process parameters for each alloy type is evaluated as disadvantage. Therefore, recently there have been many research studies for development of alternative manufacturing techniques for aluminum alloys. Research activities have shown that it is possible to improve the strength of Al-alloys remarkably by severe plastic deformation which results in ultra-fine grain size. This study aims to design and manufacture the laboratory scale set-ups for severe plastic deformation of aluminum alloys, and to characterize the severely deformed samples. The stages of the study are summarized below: First, for optimization of die design and investigation of parameters affecting the deformation finite element modeling simulations were performed. The effects of process parameters (die geometry, friction coefficient) and material properties (strain hardening, strain-rate sensitivity) were investigated. Next, Equal Channel Angular Pressing (ECAP) system that can severely deform the rod shaped samples were designed and manufactured. The variations in the microstructure and mechanical properties of 2024 Al-alloy rods deformed by ECAP were investigated. Finally, based on the experience gained, a Dissimilar Channel Angular Pressing (DCAP) system for severe plastic deformation of flat products was designed and manufactured / then, 6061 Al-alloy strips were deformed. By performing hardness and tension tests on the strips that were deformed by various passes, the capability of the DCAP set-up for production of ultra-fine grain sized high-strength aluminum flat samples were investigated.

Hoch manganhaltige Eisenbasislegierungen sind bei Raumtemperatur austenitisch und antiferromagnetisch (afm). Dabei besteht die Besonderheit, dass sich durch Legierung die afm Übergangstemperatur (Néeltemperatur) so einstellen lässt, dass sie nahe Raumtemperatur liegt. FeMn-Basislegierungen zeigen in Abhängigkeit von der Zusammensetzung Transformation Induced Plasticity (TRIP) und/oder Twinning Induced Plasticity (TWIP), d.h. die niedrige Stapelfehlerenergie dieser Legierungen führt zu verformungsinduzierter, metastabiler Phasenbildung (TRIP) bzw. zur Bildung von Verformungszwillingen (TWIP) und dadurch zu außerordentlich hoher Duktilität bei gleichzeitig hoher Verfestigung. Darüber hinaus haben FeMn-Basislegierungen einen ausgeprägten Magnetovolumeneffekt und magnetoelastischen Effekt durch magnetische Ordnung. Daher sind die untersuchten FeMnNiCr-Basislegierungen auch prototypisch für afm Élinvarlegierungen. Da Élinvar jedoch für invariable Elastizität steht, bedingt eine Anwendung als temperaturkompensierte Konstantmodullegierungen die Glättung der ausgeprägten magnetischen Anomalien, die industriell noch in keiner Anwendung realisiert wurde. Der Vorteil dies für eine Anwendung zu erreichen, läge in der Unempfindlichkeit feinmechanischer Bauelemente, gegenüber magnetischen Feldern, die bei den industriell verfügbaren ferromagnetischen Élinvarlegierungen nicht gewährleistet ist. Mit Bezug zu feinmechanischen Schwingsystemen spielen dabei neben der Einstellung der magnetoelastischen Eigenschaften die Prozessierbarkeit, Kaltumformbarkeit und Festigkeit sowie deren wechselseitige Beeinflussung eine große Rolle. Die vorliegende Arbeit befasst sich daher mit der Anwendbarkeit der untersuchten FeMnNiCr-Legierungen. Dabei wurden grundlegende Untersuchungen zur Plastizität durchgeführt, die die mechanische Zwillingsbildung in diesen Legierungen charakterisiert und ein Modell der mechanischen Zwillingsbildung bei kleinen plastischen Dehnungen vorschlägt, das eine Abschätzung der Stapelfehlerenergie erlaubt. Die Untersuchung des Antiferromagnetismus umgeformter Proben zeigt das Auftreten thermoremanenter Magnetisierung (TRM), deren Größe mit dem Umformgrad der untersuchten Proben skaliert. Sie wird den durch Umformdefekte erzeugten unkompensierten Momenten in der afm Spinstruktur zugeschrieben. Diese werden durch eine magnetische Feldkühlung magnetisiert und koppeln durch Austauschwechselwirkung an die umgebende antiferromagnetische Matrix unterhalb der Néeltemperatur. Das komplexe thermomagnetische Verhalten der unkompensierten Momente wird experimentell beschrieben und phänomenologisch gedeutet. Die Weiterentwicklung und Bewertung technischer, ausscheidbarer FeMnNiCrBe- und FeMnNiCr(Ti, Al)-Legierungen wird mit Bezug zu den grundlegenden Untersuchungen dargestellt. Es wird gezeigt, dass die neu entwickelten ausscheidbaren FeMnNiCr(Ti, Al)-Legierungen eine vielversprechende Ausgangsbasis darstellen, afm Élinvarlegierungen technisch umzusetzen. / High manganese iron-base alloys are austenitic and antiferromagnetic (afm) at room temperature. By further alloying it is possible to tune the afm transition temperature (Néel temperature) near room temperature. FeMn-base alloys show extraordinary strain hardening as well as ductility because of Transformation Induced Plasticity (TRIP) and/or Twinning Induced Plasticty (TWIP), i.e. in dependence on composition the generally low stacking fault energy in these alloys allows for the mechanically induced formation of metastable phases (TRIP) or deformation twinning (TWIP). Furthermore, magnetic order causes distinct magnetovolume and magnetoelastic effects in these afm FeMn-base alloys. The investigated FeMnNiCr-base alloys are therefore prototypic for afm Élinvar alloys. However, as Élinvar is meant for invariant elasticity, an application as temperature compensated alloy with constant elastic modulus requires the smoothing of the pronounced magnetic anomalies, that is not industrially available yet. The advantage of afm Élinvar alloys in precision mechanics applications, would be their impassiveness with respect to magnetic fields that is not achievable by their ferromagnetic counterparts. For precision components like mechanic oscillators not only the tuning of the magnetoelastic properties but also the processing, cold formability and mechanical properties as well as their interplay have strong influence. Therefore this work addresses the applicability of the studied FeMnNiCr alloys. Elementary investigations on plasticity characterise the occurrence of TWIP in these alloys and propose a modell for deformation twinning at low plastic strains that allows for an estimation of the stacking fault energy. The investigations on the antiferromagnetism of deformed samples show the appearance of thermoremanent magnetisation (TRM). Its magnitude scales with the degree of deformation. The TRM is therefore attributed to uncompensated moments in the afm spin structure due to deformation induced defects. These are magnetised by a magnetic field cooling and couple to the afm matrix by exchange interaction below the Néel temperature. The complex thermomagnetic behaviour of the uncompensated moments is experimentally described and phenomenologically explained. The further development and assessment of engineering-grade pecipitable FeMnNiCrBe and FeMnNiCr(Ti, Al) alloys is presented in relation to the aforementioned elementary investigations. It is shown that the newly developped precipitable FeMnNiCr(Ti, Al) alloys are good candidates for afm Élinvar alloys in application.

Nanotechnology offers great promise for the development of nanodevices. Hence it becomes important to study the mechanical behavior of nanostructures for their use in such systems. MEMS (Micro ElectroMechanical Systems) provide an effective and precise method for testing nanostructures. Consequently this study focuses on the development of a MEMS thermal nanotensile tester to investigate the mechanical behavior of one-dimensional nanostructures. Extensive characterization of these MEMS devices (structural, electrical and thermal behavior) was performed using experimental as well as finite element methods. Tensile testing of nanostructures requires manipulation of individual nanostructures on the MEMS device. The study involves the development of an efficient methodology for the manipulation of nanowires and nanobeams for nanoscale testing. Furthermore, two different sensing schemes for the developed devices, namely capacitive and resistive, have been extensively investigated and the advantages and various issues related to both have been discussed. Nanocrystalline (nc) Ni nanobeams (typical dimensions of 500 nm x 200 nm x 20 µm) have been tested to failure using the MEMS devices. Improvements in the design for the MEMS nanotensile tester have been suggested to significantly enhance the device performance and to resolve the various issues involved with nano scale tests. Differential capacitive sensing for stress-strain measurements has been suggested to improve the accuracy of strain measurements.

Bulk metallic glasses (BMGs) are a new class of structural materials and exhibit unique combinations of mechanical properties. As a result, their mechanical behavior has been an active area of scientific pursuit in the recent past and considerable emphasis has been paid to understand plastic deformation in them. It is now well accepted that shear transformation zones (STZs), aided by free volume, are the fundamental carriers of plasticity. At a microscopic level, deformation at low temperatures and high stresses tends to localize into shear bands. Most BMGs posses high fracture toughness despite high yield strengths and poor global ductility. However, the micro-mechanisms of fracture and fatigue in this new class of materials are not fully understood yet. The overall objective of this study is to provide insights into the fracture and fatigue response of amorphous alloys, which is important both from scientific and technological perspectives. The key questions we seek to answer through this study are the following. Do amorphous alloys undergo a ductile-brittle transition (DBT), and if so what are the reasons for it? What are the parameters that influence fatigue crack initiation in amorphous alloys and whether fatigue life can be improved by surface treatments? A related question is whether the BMGs are susceptible to deformation-induced crystallization (DIC). A Zr-based BMG, Zr41.2Ti13.75Cu12.5Ni10Be22.5 was utilized to conduct this study. By comparing the fracture and fatigue behaviors in the as-cast and annealed states {annealing was carried out below the glass transition temperature (Tg) because of established embrittlement effects}, we seek to provide answers for the questions posed above. We begin by examining the influence of temperature on the toughness of BMGs. Impact toughness measurements show that the annealed samples, which are brittle at room temperature, recover the lost toughness beyond a critical temperature (TDB) and exhibit a sharp DBT. However, the hardness remains unaffected across the TDB. Fractography reveals nano-scale patterning and cleavage fracture in the brittle state, while the formation of thick vein-patterns and shear fracture are characteristics of the ductile state of the annealed samples. We explore various micro-mechanistic possibilities for explaining the features of this transition, including a critical Poisson’s ratio-toughness correlation. Next, to understand the origins of fatigue crack initiation, we study the un-notched fatigue response of as-cast and sub-Tg annealed Zr-based BMG specimens. Because of embrittlement and nano-crystallization at the crack initiation region, the annealed specimens exhibit a lower fatigue life than the as-cast specimens. Shot-peening of the as-cast specimens did not exhibit significant improvement in their fatigue performance because of competing effects between the compressive residual stress field (CRSF) and deformation-induced softening. To further investigate surface and repeated loading effects, the tribological response of the as-cast Zr-based BMG was compared with specimens annealed above and below the Tg. A good correlation between the hardness (increasing as a function of the annealing temperature) and wear rate was obtained. The formation and peeling of the oxide layer formed during testing was the primary wear mechanism in all the specimens. Lastly, crystallization was observed within the deformed region of the as-cast Zr-based BMG repeatedly scratched with a sharp diamond indenter. But, transmission electron microscopy (TEM) does not reveal any evidence of crystallization within the indents formed within an electron transparent film formed by laser deposition of the as-cast Zr-based BMG. Absence of crystallization in deformed regions obtained by designing critical experiments, which avoid artifacts generated during sample preparation, suggests that the occasional observation of DIC might be an exception rather than the rule in BMGs.