O jateamento com granalha (shot peening) é um processo mecânico a frio onde um jato de granalhas é impelido contra a superfície dos componentes. Cada impacto provoca deformação plástica e introduz tensões residuais de compressão na superfície, as quais aumentam a sua resistência à fadiga. Este tratamento é muito usado na indústria automotiva, particularmente no tratamento de molas automotivas devido à alta solicitação a carregamentos cíclicos. Uma variante aprimorada deste processo, exclusivo para molas automotivas planas, é o jateamento com granalha sob tensão (stress peening) onde é imposta uma pré-carga de flexão na mola que aumenta a intensidade do processo. Neste trabalho foram desenvolvidas as modelagens numéricas, usando o Método dos Elementos Finitos (MEF), do jateamento com granalha e do jateamento com granalha sob tensão, ambos aplicados a molas automotivas, para analisar o campo de tensões residuais induzido. Os modelos numéricos desenvolvidos contemplam: análise dinâmica explícita, modelagem tridimensional de múltiplos impactos de granalha numa superfície plana, avaliação da velocidade real das granalhas, atrito entre as superfícies de contato, propriedades mecânicas do aço ABNT 5160 (molas automotivas), encruamento do material e sensibilidade do material às altas taxas de deformação. A partir dos resultados da modelagem foram avaliados: o progresso da cobertura ao longo do tempo da aplicação dos múltiplos impactos de granalha, as tensões residuais, as deformações elásticas e as deformações plásticas resultantes induzidas pelo jateamento. Neste trabalho, foi realizado um programa experimental para introdução e avaliação das tensões residuais em duas molas parabólicas automotivas, uma delas submetida ao jateamento com granalha e a outra submetida ao jateamento com granalha sob tensão. A avaliação experimental das tensões residuais foi desenvolvida usando as técnicas de difração de raios-X e do furo incremental cego. Os resultados das modelagens numéricas são corroborados com as medições experimentais e com os resultados experimentais e numérico-computacionais obtidos por outros autores. Finalmente, algumas conclusões são inferidas diante da análise comparativa entre os resultados numéricos e experimentais. / The shot peening is a cold-working mechanical process where a stream of tiny small balls is impelled against the surface of components. Each impact causes plastic deformation and introduces compressive residual stresses on the surface, which consequently increases their resistance to fatigue. This process is widely used in the automotive industry, particularly in the treatment of automotive springs due to high cyclic loads required. An improved variant of the shot peening process for leaf springs is the stress peening, in which a flexion pre-load is imposed to bend the spring while a conventional shot peening process is applied, resulting in an increase in the intensity of the process. In this work, numerical models of the shot peening and the stress peening process were created to be applied to automotive leaf springs. To analyze the induced residual stress field the finite elements method was used. Numerical models include: dynamic explicit formulation, three-dimensional modeling of multiple impacts of balls on a plane target, the calculation of the real shot speed, friction between the contact areas, mechanical properties of ABNT 5160 steel (for automotive leaf springs), plastic work of the material and high strain rate sensitivity of the material. The indentation coverage progress over the analyzed area, the residual stresses, the remaining elastic and plastic strains induced by the shot peening were evaluated from the modeling. In this work an experimental programme was carried out to introduce and to evaluate residual stresses in one automotive leaf spring submitted to conventional shot peening and another submitted to stress peening. The experimental evaluation of the residual stresses was done using X-ray diffraction and incremental hole drilling techniques. Results for the numerical model are compared to the experimental measurements and the experimental measurement, as well as to numerical modeling results obtained by other authors. Finally, conclusions are drawn after comparing the numerical results to experimental ones.

Single step co-sintering is proposed as a method to minimise the time and cost of fabricating solid oxide fuel cells (SOFCs). Such a methodology is attractive but challenging due to the differing sintering behaviours and thermal mismatch of the constituent materials of the anode, cathode and electrolyte in solid oxide fuel cells. As a result it is likely that compromises are made for one layer with respect to optimising another. The single chamber solid oxide fuel cell (SC-SOFC) has not seen widespread adoption due to poor selectivity and fuel utilisation, but relaxed some of the stringent SOFC requirements such as sealing, and the need for a dense electrolyte layer. Thus, to initiate the study into single step co-sintering, the single chamber SOFC is earmarked as the first candidate. The effect of single step co-sintering on cell performance is also an attractive area to investigate. Therefore, in this study, a new co-sintering process (single step co-sintering) was applied to fabricate three different types (in terms of the supporting structure) of planar SC-SOFCSs (the anode, cathode and electrolyte supported planar cells) and anode supported wavy types of SC-SOFC in order to reduce fabrication cost and time owing to effective fabrication process. In addition, their performances were tested to establish functionality of the sintered specimens as working electrochemical cells as well as to investigate the maximum performance possible with these cells under single chamber conditions. Moreover, it is also aimed to improve the performance of SC-SOFCs by extending TPB (Triple phase boundary) via wavy type. This study presents a single step co-sintering manufacturing process of planar and wavy single chamber solid oxide fuel cells with porous multilayer structures, consisting of NiO-CGO, CGO and CGO-LSCF as anode, electrolyte and cathode respectively. Pressure of 2 MPa, with the temperature at 60˚C for 5 minutes, was deemed optimal for the hot pressing of these layers. The best result of sintering profile was obtained with heating rate of 1˚C min-1 to 500˚C, 2˚C min-1 to 900˚C and 1˚C min-1 to 1200˚C with 1 hour dwelling; the cooling rate was 3˚C min-1. Hence anode supported SC-SOFC (thickness: 200:40:40 µm, thickness ratio: 10:2:2, anode (A): electrolyte (E): cathode (C)) was fabricated via a single co-sintering process, albeit with curvature formation at edges. Its performance was investigated in methane-oxygen mixtures at a temperature of 600˚C. Maximum open circuit voltage (OCV) and power density of the anode supported planar cell were obtained as 0.69 V and 2.83 mW cm-2, respectively, at a fuel-oxygen ratio of 1. Subsequently, anode thickness was increased to 800 µm and electrolyte thickness was reduced 20 µm (thickness ratio of cell 40:1:2) to obtain curvature-free anode-supported SOFCs with the help of a porous alumina cover plate placed on the top of the cell. The highest power density and OCV obtained from this cell was 30.69 mW cm-2 and 0.71 V, respectively, at the same mix ratio. In addition, the maximum residual stresses between cathode end electrolyte layers of anode supported cells after sintering were investigated using the fluorescence spectroscopy technique. The total mean residual stresses along the x-direction of the final anode supported planar cell after sintering were measured to range from -488.688 MPa to -270.781 MPa. Determination of optimum thickness and thickness ratio of the cell with the defined ideal hot pressing and sintering conditions for single step co-sintering were carried out for cathode and electrolyte supported planar cells using similar fabrication processes. Their performance changes with thickness ratio were examined. The results show that the cathode and electrolyte supported planar cells can be obtained successfully via single step co-sintering technique with the help of alumina cover plates, as with the anode supported cell. In addition, an anode supported wavy SC-SOFC was fabricated via single step co-sintering and its performance was also investigated. The maximum power density and OCV from the final curvature free cathode supported planar cell (thickness: 60:20:800 µm, thickness ratio: 3:1:20, A:E:C) was measured to be 1.71 mW cm-2 and 0.20 V, respectively, at a fuel-oxygen ratio of 1.6. Likewise, the maximum OCV and power density were found to be 0.55 V and 29.39 mW cm-2, respectively, at a fuel-oxygen ratio of 2.6, for the final electrolyte supported curvature free planar cell (thickness: 60:300:40 µm, thickness ratio: 3:15:2, A:E:C). Furthermore, a maximum OCV of 0.43 V and power density of 29.7 mW cm-2 were found from the final anode supported wavy cell (thickness: 800:20:40 µm, thickness ratio: 40:1:2, A:E:C) at a fuel-oxygen ratio of 1. In essence, this study can be divided into five chapters. The first chapter addresses the overview of the research background, problem statement, aims and objective of this study as well as that of novelty and impact. In the second chapter, fundamental information is provided regarding SOFCs and SC-SOFCs in terms of working principles, main components including electrodes electrolytes, advantages and disadvantages, types, material used for each cell components, losses in the system, and so forth. Moreover, the second chapter also contains essential sintering information in order to understand how to approach sintering of ceramics or cermet to fabricate SC-SOFCs. The overall methodology of this study is explained in detail in the third chapter while experimental works are described in the chapter 4, chapter 5, chapter 6, chapter 7 and chapter 8. Chapter 5 also contains background for the fluorescence spectroscopy and a modelling technique for residual stress measurement between ceramic layers. The results of experiments with discussion session are also in the same chapter. The last chapter presents conclusions and the possible routes for future works of the study.

Thin films are used for a variety of applications, which can include electronic devices, optical coatings and decorative parts. They are used for their physical, electrical, magnetic, optical and mechanical properties, and many times these properties are required simultaneously. Obtaining these desired properties starts with the deposition process and they are verified by a number of analysis techniques after deposition. A DC magnetron sputter system was used here to deposit tungsten films, with film thickness and residual stress uniformity being of primary interest. The film thickness was measured to vary by up to 45 % from the center to outer edge of a 4" wafer. Ar pressure was found to influence the thin film residual stress with lower Ar pressures leading to compressive residual stress (-1.5 GPa) and higher Ar pressures leading to tensile residual stress (1 GPa). Residual stress measurements of the tungsten films were made using a wafer curvature technique and X-ray diffraction. The results of the two techniques were compared and found to be within 20 %. Nanoindentation was used to analyze the mechanical properties of several types of thin films that are commonly used in microelectronic devices. Thin film reduced modulus, hardness, interfacial toughness and fracture toughness were some of the mechanical properties measured. Difficulties with performing shallow indents (less than 100 nm) were addressed, with proper calibration procedures for the indentation equipment and tip area function detailed. Pile-up during the indentation of soft films will lead to errors in the indentation contact depth and area, leading to an overestimation of the films' reduced modulus and hardness. A method was developed to account for pile-up in determining the indentation contact depth and calculating a new contact area for improving the analysis of reduced modulus and hardness. Residual stresses in thin films are normally undesired because in extreme cases they may result in thru-film cracking or interfacial film delamination. With the use of lithography techniques to pattern wafers with areas of an adhesion reducing layer, thin film delamination was controlled. The patterned delamination microchannels may be used as an alternative method of creating microchannels for fluid transport in MEMS devices. Delamination morphology was influenced by the amount of residual stress in the film and the critical buckling stress, which was primarily controlled by the width of the adhesion reducing layers.

AISI 4140 alloy steel has been a very common material to be investigated in automotive and aerospace industries for several decades. AISI 4140 alloy steel is chromium, molybdenum, and manganese containing low alloy steel. It has high fatigue strength, abrasion and impact resistance, toughness, and torsional strength. The functional performance is largely determined by the surface states after machining. The aim of the present study is to explore the polishing methods and surface analysis after machining AISI 4140 alloy steel in different cutting speeds and cooling conditions. The surface analysis includes surface roughness, hardness and residual stresses. Compared to traditional polishing, an innovative experimental work was conducted on electro-polishing technology for removing surface layer before subsurface residual stress measurement. The results of this work show that the electro-polishing method is a significant approach for the residual stress analysis. High cutting speed and cooling conditions can improve the surface quality to achieve lower surface roughness, higher microhardness and more compressive residual stresses after machining AISI 4140 alloy steel.

Nanostructured metallic multilayers (NMMs) are well-known for their high strength in smaller bilayer thicknesses. Six Al/Ti (NMM) with different individual layer thickness were tested for their mechanical hardness using a nanoindentation tool. Individual layer thicknesses were chosen carefully to cover the whole confined layer slip (CLS) model. Nano-hardness had a reverse relation with the square root of individual layer thickness and reached a steady state at ~ 5 nm bilayer thickness. Decreasing the layer bilayer thickness from ~ 104 nm to ~ 5 nm, improved the mechanical hardness up to ~ 101%. Residual stresses were measured using grazing incident X-ray diffraction (GIXRD). Effect of residual stress on atomic structure and dislocation propagation was then investigated by comparing the amount and type of stresses in both aluminum and titanium phases. Based on the gathered data from GIXRD scans tensile stress in Ti phases, and compressive stress in Al would increase the overall coherency of structure. Wear rate in coatings is highly dependent on design and architect of the structure. NMM coatings are known to have much better wear resistance compare to their monolithic constituent phases by introducing a reciprocal architect. In current study wear rate of two Al/Ti NMMs with individual layer thicknesses of ~ 2.5 nm and ~ 30 nm were examined under normal loads of 30 µN, 60 µN, and 93 µN. Wears strokes were performed in various cycles of 1, 2, 3, 4 5 and 10. Wear rates were then calculated by comparing the 3D imaging of sample topology before and after tests. Nano-hardness of samples was measured pre and post each cycle of wear using a nanoindentation tool. The microstructure of samples below the worn surface was then characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM), atomic force microscopy (AFM), focus ion beam (FIB) and an optical profilometer. Orientation mapping was performed to analyze the microstructure of layers beneath the nano indents. TEM imaging from the cross section of worn samples indicated severely plastically deformed layer (SPDL) below the worn surface. Shear bands and twins are visible after wear and below the worn surface. Decreasing the layer thickness from 30 nm to 2.5 nm resulted in ~ 5 time’s better wear resistance. Nanowear caused surface hardening which consequently increased nano hardness up to ~ 30% in the sample with 2.5 nm individual layer thickness. Increasing the interfaces density of NMMs will significantly improve the corrosion resistance of coating. Reciprocal layers and consequently interfaces will block the path of aggressive content toward the substrate. Corrosion rate evolution of Al/Ti multilayers was investigated through DC corrosion potentiodynamic test. Results seem to be very promising and demonstrate up to 30 times better corrosion resistance compared to conventional sputtered monolithic aluminum. Corrosion started in the form of pitting and then transformed to the localized galvanic corrosion. Decreasing the bilayer thickness from ~ 10.4 nm to ~ 5 nm will decrease the corrosion current density (icorr) of ~ 5.42 × 10-7 (A/cm2) to ~ 6.11 × 10-10 (A/cm2). No sign of corrosion has been seen in the sample with ~ 2.5 nm individual layer thickness. Further AFM and TEM analysis from surface and cross section of NMMs indicate that a more coherent layer by layer structure improves the corrosion rate. Interfaces have a significant role in blocking the pores and imperfections inside coating.

MEMS-based gas turbine engines are currently under development at MIT for use as a button-sized portable power generator or micro-aircraft propulsion sources. Power densities expected for the micro-engines require very high rotor peripheral speeds of 300-600m/s and high combustion gas temperatures of 1300-1700K. These harsh requirements for the engine operation induce very high stress levels in the engine structure, and thus call for qualified refractory materials with high strength. Silicon carbide (SiC) has been chosen as the most promising material for use due to its high strength and chemical inertness at elevated temperatures. However, the state-of-the art microfabrication techniques for single-crystal SiC are not yet mature enough to achieve the required level of high precision of micro-engine components. To circumvent this limitation and to take advantage of the well-established precise silicon microfabrication technologies, silicon-silicon carbide hybrid turbine structures are being developed using chemical vapor deposition (CVD) of thick SiC (up to ~70µm) on silicon wafers and wafer bonding processes. Residual stress control of thick SiC layers is of critical importance to all the silicon-silicon carbide hybrid structure fabrication steps since a high level of residual stresses causes wafer cracking during the planarization, as well as excessive wafer bow, which is detrimental to the subsequent planarization and bonding processes. The origins of the residual stress in CVD SiC layers have been studied. SiC layers (as thick as 30µm) with low residual stresses (on the order of several tens of MPa) have been produced by controlling CVD process parameters such as temperature and gas ratio. Wafer-level SiC planarization has been accomplished by mechanical polishing using diamond grit and bonding processes are currently under development using CVD silicon dioxide as an interlayer material. This paper reports on the work that has been done so far under the MIT micro-engine project. / Singapore-MIT Alliance (SMA)

Fatigue assessments have been carried out predominantly with quasi-deterministic approaches, such as the use of SN curves. However, both the loading and the resistance of fatigue prone components are subjected to significant uncertainties. Consequently, a prediction of the remaining fatigue life based on deterministic load and resistance models can lead to unreliable results. This work presents a general reliability-based approach to predict fatigue life of steel components. The approach incorporates prediction of fatigue crack initiation, modeled with a strain-based correlation approach, and propagation, modeled using a linear elastic fracture mechanics approach, and is applicable to new, cracked or repaired structural components. Based on the analysis of existing test results and additional crack initiation and propagation tests on weld metal, the relevant probabilistic fatigue material properties of grade 350WT steel and a matching weld metal were established. An experimental program was carried out on welded details tested either in the as-welded, stress-relieved, conventionally peened, or ultrasonically peened condition. It was demonstrated that ultrasonic peening is superior to the other investigated post weld treatment methods. Using finite element analyses, the results of the tests were deterministically predicted for several different initial conditions, including initial flaw and crack sizes and locations, as well as different levels of residual stresses. A model incorporating an initial flaw and accounting for crack closure and the threshold stress intensity factor range was retained. A probabilistic analysis using Monte Carlo Simulation was carried out to calibrate the relevant parameters. A general reliability-based approach, which includes both the loading and resistance sides of the limit state function was proposed and applied to three practical examples: prediction of test results from two test programs and the prediction of the remaining fatigue life of a cracked component as a function of the safety index. These three applications demonstrated that accurate fatigue life predictions targeting a predefined safety index are achieved. / Structural Engineering

In this study, effect of fillet rolling process on fatigue performance of a diesel engine crankshaft was investigated. Crankshafts from two different materials, were studied / ductile cast iron EN-GJS 800-2 and micro-alloyed steel 38MnVS6. Resonance bending fatigue tests were conducted with crankshaft samples. Test plan according to staircase test methodology was used. Statistical analyses were carried out with the test data by Maximum Likelihood Estimation method in order to calculate the fatigue limits and construct the S-N curves based on Random Fatigue Limit (RFL) and Modified Basquin models. Fatigue limit calculations were also conducted by Dixon-Mood method and by Maximum Likelihood Estimation methodology for Normal and Weibull distributions. Fillet rolling process was simulated by computer based analysis in order to calculate the compressive residual stress profile at the fillet region to shed more light on the mechanisms and effect of fillet rolling. Fatigue performances of crankshafts from two types of materials were evaluated both at unrolled and fillet rolled states. Effect of fillet rolling load on fatigue performance was also evaluated with steel crankshafts. It was found that ductile cast iron showed better performance under bending fatigue tests than the steel crankshaft both at the fillet rolled and unrolled conditions. On the other hand, fillet rolling process was found to be more effective on steel crankshaft than ductile cast iron crankshaft in terms of fatigue performance improvement. It was also seen that fatigue limit increases with the fillet rolling load up to a limit where surface quality is deteriorated. Residual stress analysis showed that a higher magnitude of residual stress can develop on steel crankshaft fillet region whereas the effective depth of the residual stress is higher on ductile cast iron crankshaft with the same rolling condition. Residual stress analysis of steel crankshafts rolled at different rolling conditions show that, peak residual stress increase with the increasing rolling load is not significantly high and main effect of increased rolling load is the increased effective depth of residual stresses. The MLE methodology used in statistical analysis of the test data was found to be effective for life regression and fatigue strength distributions analysis. RFL model has provided better life regression analysis and fatigue limit calculations than Modified Basquin model. Dixon-Mood method was found to be overestimating the fatigue limit.

Yttria Partially Stabilized Zirconia (Y-PSZ) plasma-sprayed coatings are widely used in turbine engines as thermal barrier coatings. However, in diesel engines Y-PSZ TBCs have not met with wide success. To reach the desirable temperature of 850-900˚C in the combustion chamber from the current temperature of 400-600˚C, a coating with a thickness of approximately 1mm is required. This introduces different considerations than in the case of turbine blade coatings, which are on the order of 100µm thick. Of the many factors affecting the durability and failure mechanism of TBCs, in service and residual stresses play an especially important role as the thickness of the coating increases. For decreasing the residual stress in the system, a multi-layer coating is helpful. The design of a multilayer coating employing relatively low cost materials with complementary thermal properties is described. Numerical models were used to describe the residual stress after deposition and under operating conditions for a multilayer coating that exhibited the desired temperature gradient. Results showed that the multilayer coating had a lower maximum stress under service conditions than a conventional Y-PSZ coating. Model validation with experiments showed a good match between the two.

Yttria Partially Stabilized Zirconia (Y-PSZ) plasma-sprayed coatings are widely used in turbine engines as thermal barrier coatings. However, in diesel engines Y-PSZ TBCs have not met with wide success. To reach the desirable temperature of 850-900˚C in the combustion chamber from the current temperature of 400-600˚C, a coating with a thickness of approximately 1mm is required. This introduces different considerations than in the case of turbine blade coatings, which are on the order of 100µm thick. Of the many factors affecting the durability and failure mechanism of TBCs, in service and residual stresses play an especially important role as the thickness of the coating increases. For decreasing the residual stress in the system, a multi-layer coating is helpful. The design of a multilayer coating employing relatively low cost materials with complementary thermal properties is described. Numerical models were used to describe the residual stress after deposition and under operating conditions for a multilayer coating that exhibited the desired temperature gradient. Results showed that the multilayer coating had a lower maximum stress under service conditions than a conventional Y-PSZ coating. Model validation with experiments showed a good match between the two.