Shot peening is a cold-working process by which residual compressive stresses are being induced in the surface region to increase the fatigue strength and the resistance to stress-corrosion cracking. This study covers non-destructive measurement of surface residual stresses in the shot-peened steel components by a micro-magnetic technique, named as Magnetic Barkhausen Noise (MBN) method. For this purpose, various low alloy steel specimens were prepared by a controlled shot peening process with different intensity, impact angle and coverage values. The measurements showed that a clear relationship exists between residual stresses and the MBN signals. Residual stress values determined by MBN technique were also verified by X-ray diffraction measurements.

Strain engineering is used as a means of manufacturing micro- and nano- scale particles with the ability to reversibly alter their geometry from three dimensional tubes to two dimensional flat layers. These particles are formed from a bi-layer of two dissimilar materials, one of which is the elastomeric material polydimethylsiloxane (PDMS), deposited under stress on a sacrificial substrate. Upon the release of the bi-layer structure from the substrate, interfacial residual stress is released resulting in the formation of tubes or coils. These particles possess the ability to dramatically alter their geometry and, consequently, change some properties that are reversible and can be triggered by a stimulus. This work focuses on the material selection and manufacturing of the bi-layer structures used to create the responsive particles and methods for characterizing and controlling the responsive nature of the particles. Furthermore, the potential of using these particles for a capture/release application is explored, and a systematic approach to scale up the manufacturing process for such particles is provided. This includes addressing many of the problems associated with fabricating ultra-thin layers, tuning the size of the particles, understanding how the stress accumulated at the interface of a bi-layer structure can be used as a tool for triggering a response as well as developing methods (i.e. experiments and applications) that allow the demonstration of this response.

The goal of this research was to investigate an experimental infrared transmission technique to extract the full stress components of the in-plane residual stresses in thin multi crystalline silicon wafer, and try to meet the need of photovoltaic industry to in situ measure residual stress for large cast wafers.

<p>In this thesis structural optimization of castings and thermomechanical analysis of castings are studied.</p><p>In paper I an optimization algorithm is created by using Matlab. The algorithm is linked to the commercial FE solver Abaqus by using Python script. The optimization algorithm uses the successive response surfaces methodology (SRSM) to create global response surfaces. It is shown that including residual stresses in structural optimization of castings yields an optimal shape that differs significantly from the one obtained when residual stresses are excluded.</p><p>In paper II the optimization algorithm is expanded to using neural networks. It is tested on some typical bench mark problems and shows very promising results. Combining paper I and II the response surfaces can be either analytical functions, both linear and non-linear, or neural networks. The optimization is then performed by using sequential linear programming or by using a zero-order method called Complex. This is all gathered in a package called StuG-OPT.</p><p>In paper III and IV focus is on the thermomechanical problem when residual stresses are calculated. In paper III a literature review is performed and some numerical simulations are performed to see where numerical simulations can be used in the industry today. In paper IV simulations are compared to real tests. Several stress lattices are casted and the residual stresses are measured. Simulations are performed by using Magmasoft and Abaqus. In Magmasoft a J2-plasticity model is used and in Abaqus two simulations are performed using either J2-plasticity or the ”Cast Iron Plasticity” available in Abaqus that takes into account the different behavior in tension and compression for grey cast iron.</p> / Report code: LIU-TEK-LIC-2007:34.

In this work the author presents simulation procedures (mathematical models) with the aim to help determining and analysing the mechanical properties of coating-substrate-systems and finding an “optimal” coating structure which should protect the compound from inelastic deformation under a given range of load conditions. Such procedures may be used as a tool to minimise the search field for experimental work. For this purpose one would need a mathematical model which allows one to calculate the complete elastic field with all its displacement and stress components within a multilayer film on a substrate under given mechanical loading and intrinsic stress conditions. Due to copyright restrictions the author is not allowed to publish the Part II of his habilitation thesis at this place. It concerns the references in meta data. / In der Arbeit werden mathematische Modelle zur Berechnung der mechanischen Eigenschaften geschichtet aufgebauter Materialien unter unterschiedlichsten Lastbedingungen (Kontakt- und intrinsische Beanspruchung) vorgestellt und diskutiert. Auf Grund von Schutzrechtsbestimmungen ist eine Veröffentlichung der in der Habilitation angegebenen Literatur im Teil II an dieser Stelle nicht möglich. Der interessierte Leser wird gebeten die Arbeiten in den entsprechenden Journalen einzusehen. Dies betrifft die in den Metadaten angegebenen Veröffentlichungen des Autors.

Thesis (Ph. D.)--University of Missouri-Columbia, 2000. / Typescript. Vita. Includes bibliographical references (leaves 182-188). Also available on the Internet.

The simulation and design of advanced materials for fatigue resistance requires an understanding of the response of their hierarchical microstructure attributes to imposed load, temperature, and environment over time. For Ni-base superalloy components used in aircraft jet turbine engines, different competing mechanisms (ex. surface vs. subsurface, crystallographic vs. inclusion crack formation, transgranular vs. intergranular propagation) are present depending on applied load, temperature, and environment. Typically, the life-limiting features causing failure in Ni-base superalloy components are near surface inclusions. Compressive surface residual stresses are often introduced in Ni-base superalloy components to help retard fatigue crack initiation and early growth at near surface inclusions and shift the fatigue crack initiation sites from surface to sub-surface locations, thereby increasing fatigue life. To model the effects of residual stresses, inclusions, and microstructure heterogeneity on fatigue crack driving force and fatigue scatter, a computational crystal plasticity framework is presented that imposes quasi-thermal eigenstrain to induce near surface residual stresses in polycrystalline Ni-base superalloy IN100 smooth specimens with and without nonmetallic inclusions. In addition, the effect of near surface inclusions in notched Ni-base superalloy components on MSC growth and fatigue life scatter was investigated in this work. A fatigue indicator parameter (FIP)-based microstructurally small crack (MSC) growth model incorporating crack tip/grain boundary effects was introduced and fit to experiments (in both laboratory air and vacuum) for the case of 1D crack growth and then computationally applied to 3D crack growth starting (1) from a focused ion beam (FIB) notch in a smooth specimen, (2) from a debonded inclusion located at different depths within notched components containing different notch root radii, and (3) from inclusions located at different depths relative to the surface in smooth specimens containing simulated shot peened induced residual stresses. Computational predictions in MSC growth rate scatter and distribution of fatigue life were in general accordance with experiments. The general approach presented in this Dissertation can be used to advance integrated computational materials engineering (ICME) by predicting variation of fatigue resistance and minimum life as a function of heat treatment/microstructure and surface treatments for a given alloy system and providing support for design of materials for enhanced fatigue resistance. In addition, this framework can reduce the number of experiments required to support modification of material to enhance fatigue resistance, which can lead to accelerated insertion (from design conception to production parts) of new or improved materials for specific design applications. Elements of the framework being advanced in this research can be applied to any engineering alloy.

Methodology of stress measurements with multireflection grazing incidence method (MGIXD)was investigated and developed. The parallel beam geometry was applied. The incident beam in classicaldiffractometers was collimated by Göbel mirror and the tests of parallel configuration were performed for Alpowder. Results confirmed that both statistical error and the misalignment error can be reduced when theGöbel mirror is used. Physical factors were taken into account in XSA (X-ray stress analysis): Lorentzpolarizationand absorption factor (LPA) and also refraction correction (RC). Results showed that theinfluence of LPA correction is minor in XSA but the RC can significantly influence analysis. In the thesisthe issue of RC was considered and compared with approaches presented in the literature. In the thesistwo theoretical developments of the MGIXD method were presented: the procedure of c/a parameterdetermination and the influence of stacking faults on the results was taken into account. It was shown thatboth developments significantly improves the quality of experimental data analysis. In the present work theproblem of X-ray stress factors (XSF) used for the interpretation of XSA results was studied. Differenttheoretical grain elasto-plastic interaction models were considered and applied in XSA. Verification of theXSF was during tensile test for austenitic stainless steel and for the isotropic sample. Anisotropy of XSFwas also observed in: ground Ni alloy, polished austenitic stainless steel and CrN coating. The resultsshows that Reuss and free surface grain interaction models are in the best agreement with theexperimental results. Finally the MGIXD method was verified using synchrotron radiation and 3 differentwavelengths. The methodology was developed to treat data not only for different incident angles but alsousing simultaneously different wavelengths. Stresses vs. z - 'real depth' was calculated using the inverseLaplace transform applied to polynomial function. Wiliamson-Hall analysis was applied for collected data.Next multireflection method was applied for the energy dispersion diffraction measurements in which whitebeam containing radiation having different wavelengths was used (λ (Ǻ): 0.3-0.18/ E (keV): 40-68). Thestress analysis was performed using three different methods: standard sin2ψ method, Universal plotmethod and by using multireflection analysis. In the range of penetration depth to 0-15 μm theconvergence of the results obtained from different methods was gained. Moreover the synchrotron dataperfectly agree with the results obtained on laboratory diffractometer (Cu Kα radiation) close to the surface.For depth larger than 14 μm the experimental points exhibit significant spread and do not agree with theresults of standard method

The goal of this research was to examine the relationship between dislocation density and in-plane residual stress in edge-defined film-fed growth (EFG) silicon wafers. Previous research has shown models for linking dislocation density and residual stress based on temperature gradient parameters during crystal growth. Residual stress and dislocation density have a positive relationship for wafers with very low dislocation density such as Cz wafers. There has been limited success in experimental verifications of residual stress for EFG wafers, without any reference to dislocation density. No model of stress relaxation has been verified experimentally in post production wafers. A model that assumes stress relaxation and links residual stress and dislocation density without growth parameters will be introduced here. Dislocation density and predominant grain orientation of EFG wafers have been measured by the means of chemical etching/optical microscope and x-ray diffraction, respectively. The results have been compared to the residual stress obtained by a near infrared transmission polariscope. A model was established to explain the results linking dislocation density and residual stress in a randomly selected EFG wafer.

Thesis (M.S.)--Ohio University, June, 2000. / Title from PDF t.p.