Para muitos componentes e estruturas de engenharia a determinação precisa do estado de tensões residuais presente é de fundamental importância para a avaliação de sua integridade estrutural. O método do furo cego (MFC) é um dos métodos mais difundidos para a medição de tensões residuais, no entanto, por se tratar de um ensaio relativamente complexo, a determinação da sua incerteza de medição apresenta uma série de dificuldades, as quais se refletem na inexistência de estudos na literatura que abordem esse assunto de forma completa. Este trabalho tem como objetivo a determinação da incerteza de medição do MFC englobando todas as fontes de incerteza em potencial do método. Para tanto, foi elaborado um procedimento envolvendo a determinação e caracterização das fontes de incerteza tanto na parte experimental como no tratamento matemático dos dados. A partir da caracterização das fontes de incerteza detectou-se como fator principal na determinação da incerteza o erro do operador, que foi possível através do desvio de repetitividade. A fonte de incerteza devido ao erro do operador foi a de determinação mais complexa e envolveu o projeto e a construção de uma máquina especialmente desenvolvida para a aplicação de um estado de tensões homogêneo e que permitisse medir com precisão as tensões residuais com o método do furo cego. Técnicas de medição de tensões residuais por difração de raios-X e monitoramento de tensão com extensometria de resistência elétrica foram utilizadas para a verificação da homogeneidade das tensões nas amostras. A metodologia se mostrou adequada, conduzindo a resultados que permitiram determinar com sucesso a incerteza de medição através de planilhas eletrônicas. / The characterization of the residual stress state of engineering components and structures is of fundamental importance for assessments of their structural integrity. The hole drilling method is one of the most commonly used methods; however, due to its relative complexity, quantifying its measurement uncertainties is not straightforward. It is a semi-destructive method, which means that multiple measurements cannot be repeated in a same location, and stress distributions mean that it is difficult to guarantee that a number of points in the same state will be available in a given volume. This study suggests a global uncertainty measurement which includes a study of repeatability related to the operator. This is thought to be novel in the existing literature. For this, a standard sample and a machine which guarantees a homogeneous stress distribution in the sample were developed. To ensure the homogeneity of the stresses, x-ray diffraction measurements were performed. The results obtained show good repeatability for different operators and good results for the uncertainty of measurements for the method.

Os aços inoxidáveis austeníticos são materiais atrativos para serem utilizados em vários setores industriais que operam sob meios corrosivos, como por exemplo: indústria química, alcooleira, petroquímica, de papel e celulose, na prospecção de petróleo e nas indústrias têxtil e farmacêutica. Contudo, apresentam propriedades tribológicas pobres. No sentido de melhorar essas propriedades, como aumentar a dureza superficial, a resistência ao desgaste e a resistência à fadiga, vários métodos de tratamentos superficiais vêm sendo utilizados. Dentre eles, o mais eficiente é a nitretação por plasma. Este processo é realizado em uma câmara de vácuo sob uma mistura gasosa de hidrogênio e nitrogênio. É aplicada uma diferença de potencial entre o cátodo (porta amostras) e o ânodo (paredes da câmara), acelerando os íons contra a superfície da peça, aquecendo-a e arrancando elétrons de sua superfície. Os íons reagem com espécies da superfície do plasma formando compostos instáveis do tipo FeN que se recombinam para formarem nitretos estáveis. O sucesso deste tratamento se deve à baixa temperatura de operação, ao menor tempo efetivo de tratamento e ao controle da uniformidade da espessura da camada. A camada de nitretos formada durante o tratamento possui uma influência positiva na vida em fadiga de um componente, graças a dois motivos principais. O primeiro é o atraso na nucleação da trinca devido ao aumento da resistência mecânica superficial. O segundo motivo está relacionado com a introdução de tensões residuais compressivas durante o processo de endurecimento da superfície, que retarda a iniciação da trinca e diminui o fator de intensidade de tensão. Os corpos de prova foram nitretados a 400ºC durante 6 horas, com uma pressão de 4,5 mbar e utilizando uma mistura gasosa de 80% vol.H2 e 20%vol.N2. Ocorreu um aumento da resistência mecânica próxima á superfície, devido à camada de nitretos, o que ficou evidente com o sensível aumento no valor do limite de fadiga do material nitretado em relação ao não nitretado. O limite de fadiga do aço AISI 316 não tratado foi de 400MPa e do nitretado foi de 510MPa, enquanto que, para o aço AISI 304, o limite de fadiga do material não tratado foi de 380MPa e o limite para material submetido ao tratamento de nitretação foi de 560MPa. / The austenitic stainless steels are attractive materials to many industrial sectors which work on corrosive environments, as chemical industry alcohol, petrochemical, cellulose industries, in the petroleum prospection and pharmaceutical and textiles industries. However, they present poor tribological properties. In order to improve these properties, like increasing superficial hardness, wear and fatigue resistance superficial heat treatment methods have being used. The most efficient is the plasma nitriding process which occurs in a vacuum container under hydrogen and nitrogen gas mixture. A potential difference is applied between the cathode (samples receptor) and the anode (container walls), accelerating the ions against the piece, heating it and removing electron from the surface of material. These atoms react with the surface plasma species, producing unstable compounds like FeN, which recombine producing stable nitrides. The success of this treatment is due to the low temperature operation, the short effective time of treatment and to the uniformity control of the layer’s thickness. The nitrides layer produced during the treatment have a positive influence in the fatigue life of a component, thanks to two main reasons. The first is the retardation in crack nucleation due to increasing of superficial mechanical strength. The second reason is due to introduction of compressive residual stress during the surface hardening process, which retards de crack initiation process. The specimens were nitriding at 400°C during 6 hours, at a 4,5mbar pressure and using a gas mixture of 80% vol. H2 and 20% vol. N2. The surface mechanical strength increased, due to the nitrides layer, which was evident with the sensitive increase in the fatigue limit of the nitriding specimens, comparing to the untreated ones. The fatigue limit of the AlSl 316 steel in untreated condition was 400 MPa and in nitriding condition was 510 MPa, whereas AlSl 304 steel, the fatigue limit of the untreated condition was 480 MPa and the fatigue limit for the nitrided condition was 560 MPa.

This diploma thesis deals with simulation of cross-roll straightening using computational modeling with finite element method in software ANSYS. The main goal of this thesis is to quantify the influence of inaccurate knowledge of mechanical properties on the straightening process and correct setting of machine. It also aims for comparison of hardening models and their influence on the final curvature and residual stresses in the cross section of the bar.

Lorsqu’un alliage métallique est mis sous une atmosphère oxydante à haute température, un oxyde est formé en surface de l’alliage. La résistance à l’oxydation à haut température est un critère très important pour le choix des alliages. Il a été observé que le comportement à l'oxydation des alliages sous l'atmosphère avec vapeur d'eau est différente de celle dans l'air sec ou dans l'oxygène. En outre, les contraintes de croissance (générées au cours de l’oxydation isotherme) et les contraintes thermiques (générées au cours du refroidissement) sont formées dans la couche d'oxyde. Ces contraintes ont des effets importants sur la durée de vie de l'alliage. Le présent travail se concentre essentiellement sur l'étude de l'influence de la vapeur d'eau sur le comportement à l'oxydation de l’alliage AISI 430 à haute température, qui est importante pour les applications dans la pile à combustible SOFC (solid oxide fuel cell) comme interconneteurs. Les expériences d'oxydation de l’alliage AISI 430 sous air sec et sous air avec différentes humidités absolues (2%-10%) de 700°C à 900°C sont réalisées à l’aide de l’analyse thermogravimétrique (ATG). Les images MEB des échantillons ont été obtenues avec un MEB-FEG avec un microanalyseur X par dispersion d’énergie (EDX). Les contraintes résiduelles de la couche d’oxyde sont obtenues par la Diffraction des Rayons X (DRX) à la température ambiante, et la méthode de déflexion a été utilisée pour déterminer les contraintes de croissance. Après l’introduction de vapeur d’eau dans l’atmosphère d’oxydation, les comportements à l’oxydation de l’alliage AISI 430 à haute température ont été affectés. La présence de vapeur d’eau modifie donc le niveau de contraintes résiduelles dans la couche d’oxyde. La dégradation de la couche d’oxyde est observée après une courte durée d’oxydation à 900°C et deux mécanismes possibles sont proposés pour expliquer ce phénomène à partir de nos résultats d’étude. / When an alloy is placed in an atmosphere containing oxygen at high temperature, the formation of oxide scale may take place. The oxidation resistance of the alloy is a very important criterion for selecting alloys to be used at high temperature. And it has been found that the oxidation behavior of alloys in atmosphere containing water vapor is different from that in dry air or oxygen. Moreover, in the oxide scale systematically accompanied the development of growth stresses during isothermal oxidation and of thermal stresses during cooling, which also limit the durability of oxide scale and the lifetime of the alloy. The purpose of this work is to investigate the influence of water vapor on oxidation behavior of AISI 430 stainless steel at high temperature, which is expected to be used as interconnectors in the planar solid oxide fuel cells (SOFCs). The oxidation experiments have been performed in air with different absolute humidity (2%-10%) at 700°C, 800°C and 900°C by thermal gravimetric analysis (TGA) system. The oxide surface morphology, cross-section microstructure and the chemical composition of the oxide scale were studied after oxidation by FEG-SEM and EDX. The residual stresses distributions in the oxide scale were determined at room temperature by XRD method after oxidation, and the growth stresses were measured by in-situ deflection method during oxidation. It has been found that the oxidation kinetic, surface morphology and diffusion mechanism of AISI 430 stainless steel in dry air are changed with the introduction of water vapor. The water vapor can also influence the residual stresses levels in the oxide scale. In the presence of water vapor, breakaway oxidation was observed at 900°C, and two possible mechanisms were given to explain this.

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.

Composite materials with laminated structure provide advantages which are utilised during component design. Low density, temperature and chemical stability are the profitable properties predetermining application of ceramic laminates. The main obstacle for wide spread of ceramic materials is their inherent brittleness. Therefore, in this thesis, the crack propagation in ceramics laminates has been extensively studied. Laminated structures with various volume fractions of components (alumina and zirconia) were prepared by electrophoretic deposition. Evaluation of crack propagation through the interface and determination of basic mechanical properties was conducted on the basis of extensive literature search. Crack deflection originated in both presence of internal stresses and differences in elastic modulus during the crack interface passing was monitored. A special type of specimen geometry was employed with the aim to set arbitrary angle between crack and interface. It was experimentally found that the degree of crack deflection is dependent on entering angle and volume fraction of components. Higher crack deflection was already found in the bulk of the test piece comparing to the test piece surface. The 3D fracture surface reconstruction generated using laser confocal microscopy was used in this detailed crack propagation study. Further basic elastic and strength characteristics of laminates were determined and compared to those obtained from monolithic materials. The validity of the mix rule for elastic characteristics was confirmed by comparing of elastics modulus. The most reliable method for elastic modulus determination was marked the dynamic resonance method due to low scatter and consistency in measurement. The flexural strength of all laminates tends to be close to the flexural strength of the weakest component. Therefore the mix rule is not applicable for flexural strength estimation on the contrary of elastic characteristics. The change of component volume fraction leads only to change of flexural strength scatter. Thanks to gained knowledge about crack propagation and basic characteristic determination will be possible to design ceramic laminates more efficiently for given needs of application.

This comprehensive study is the first to quantify the fatigue performance, failure loads, and microstructure of resistance spot welding (RSW) in 6061-T6 aluminum (Al) alloy according to welding parameters and process sensitivity. The extensive experimental, theoretical and simulated analyses will provide a framework to optimize the welding of lightweight structures for more fuel-efficient automotive and military applications. The research was executed in four primary components. The first section involved using electron back scatter diffraction (EBSD) scanning, tensile testing, laser beam profilometry (LBP) measurements, and optical microscopy(OM) images to experimentally investigate failure loads and deformation of the Al-alloy resistance spot welded joints. Three welding conditions, as well as nugget and microstructure characteristics, were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that increasing the applied welding current deepened the weld imprints. The EBSD scans revealed the strong dependency between the grain sizes and orientation function on the process parameters. For the second section, the fatigue behavior of the RSW’ed joints was experimentally investigated. The process optimization included consideration of the forces, currents, and times for both the main weld and post-heating. Load control cyclic tests were conducted on single weld lap-shear joint coupons to characterize the fatigue behavior in spot welded specimens. Results demonstrate that welding parameters do indeed significantly affect the microstructure and fatigue performance for these welds. The third section comprised residual strains of resistance spot welded joints measured in three different directions, denoted as in-plane longitudinal, in-plane transversal, and normal, and captured on the fusion zone, heat affected zone and base metal of the joints. Neutron diffraction results showed residual stresses in the weld are approximately 40% lower than the yield strength of the parent material, with maximum variation occurring in the vertical position of the specimen because of the orientation of electrode clamping forces that produce a non-uniform solidification pattern. In the final section a theoretical continuum modeling framework for 6061-T6 aluminum resistance spot welded joints is presented.

[pt] A fotoelasticidade é uma ferramenta poderosa para análise de tensões em problemas bi e tridimensionais. Nos últimos anos a técnica vem ganhando renovado interesse da comunidade científica devido à adaptação de modernas técnicas de aquisição e processamento digital de imagens. Uma das linhas mais promissoras é a Fotoelasticidade RGB, que entende a cor como uma combinação única dos níveis de intensidade das componentes Red, Green e Blue. Tratase de uma metodologia poderosa, porém de fácil compreensão e aplicação em ambientes industriais. Uma aplicação tradicional da fotoelasticidade é na inspeção de tensões residuais em componentes de vidro, utilizando-se a Norma ASTM F218. Esta Norma estabelece dois procedimentos para a determinação da ordem de franja isocromática: um quantitativo e outro qualitativo. O vidro tem birrefringência muito baixa, o que faz com que a resposta ótica seja basicamente em tons de cinza. No seu procedimento qualitativo a Norma ASTM F218 recomenda a utilização de um filtro retardador de onda inteira. Com esse simples procedimento, a resposta ótica se modifica. No lugar de tons de cinza tem-se cores em torno da passagem do vermelho para o azul, o que simplifica muito a análise de birrefringência por um operador. A aplicação da Fotoelasticidade RGB para componentes de vidro, transforma este método qualitativo em quantitativo: a cor deixa de ser um parâmetro abstrato, e passa a ser um número. Este trabalho analisa os procedimentos necessários para aplicar a Fotoelasticidade RGB à indústria do vidro. A Norma ASTM F218 recomenda que o filtro de onda inteira, seja inserido com sua direção principal alinhada à direção principal de cada ponto analisado. Foi pesquisada a diferença entre os resultados obtidos, quando a norma é seguida, e quando é utilizado um procedimento simplificado, ou seja, é utilizada apenas uma posição do filtro para analisar todos os pontos. Além disso, o método foi aplicado a dois casos: um esteme e um bulbo de lâmpada. Nos dois casos, foram analisados um componente considerado bom e outro considerado ruim, por seu fabricante, procurando mostrar seus estados de tensões residuais através da Fotoelasticidade RGB. / [en] Photoelasticity is a powerful tool for analyzing stress in bidimensional and three-dimensional problems. In the last years the technique renewed the scientific community s interest due to adaptation of modern acquisition and image digital processing techniques. One of the most promising field is called RGB Photoelasticity. It quantifies the color as an unique combination of the intensity levels of Red, Green and Blue components. It is a powerful methodology,even so of easy understanding and application in industrial enviroment.A traditional application of the photoelasticity is in the inspection of residual stresses in glass components, using the specification ASTM F218. That specification establishes two procedures for the determination of the isocromatics fringe order: one of them quantitative and anotehr one qualitative. The glass has very low birefringence, so that its optic response is basically in gray tones. In the qualitative procedure the specification F218 recommends the use of a full - wave plate. With this simple procedure the optical answer is changed. It is possible to obtain colors near the passage of the red to blue, what simplifies the analysis too much. The application of RGB photoelasticity to glass transforms the qualitative method in quantitative: the color is not more an abstract parameter, but a number. This dissertation analyzes the necessary procedures to apply RGB photoelasticity to the glass industry. The specification F218 recommends that the full wave plate must be inserted with its principal direction aligned to the principal direction of each analyzed point. A implification to that procedure was proposed: to use only one position of the filter to analyze all the points. The difference among the two procedure was researched; the results obtained following the specification and using the simplified procedure were compared. The method has been applied to two cases: a stem and a lamp bulb. In the both cases, a component in the acceptable condition and another in the non-acceptable condition were analyzed, in order to show their states of residual stresses using the RGB photoelasticity.

Ultra-high temperature ceramics (UHTCs), such as ZrB2-based ceramic composites, have been identified as next generation candidate materials for leading edges and nose cones in hypersonic air breathing vehicles. Mechanical performance of ceramic composites play an important role in the ultra-high temperature applications, therefore SiC is added to ZrB2 as a strengthening phase to enhance its mechanical performance. The high melting temperatures of both ZrB2 and SiC, as well as the ability of SiC to form SiO2 refractory oxide layers upon oxidation make ZrB2-SiC ceramics very suitable for aerospace applications. Thermal residual stresses appearing during processing are unavoidable in sintered ZrB2-SiC ceramic composites. Residual microstresses appear at the microstructural level (intergranular microstresses) or at the crystal structure level (intragranular microstresses). These microstresses are of enormous importance for the failure mechanisms in ZrB2-SiC ceramics, such as ratio of the trans- and intergranular fracture; crack branching or bridging, microcracking, subcritical crack growth and others, as they govern crack propagation–induced energy dissipation and affect the toughness and strength of the ceramic material. Therefore, understanding the evolution of residual stress state in processed ZrB2-SiC ceramic composites and accurate measurements of these stresses are of high priority. In the present research the ZrB2-17vol%SiC, ZrB2-32vol%SiC, and ZrB2-45vol%SiC ultra-high temperature particulate ceramic composites were sintered using both Hot Pressing (HP) and Spark Plasma Sintering (SPS) techniques. The mechanical performance of the ZrB2-SiC composites was investigated using 3- and 4-point bending techniques for measurements of instantaneous fracture strength and fracture toughness. Resonant Ultrasound Spectroscopy was used for measurement of Young's, shear, and bulk moduli as well as Poisson's ratio of the composites. The distribution of thermal residual stresses and the effect of the applied external load on their re-distribution was studied using micro-Raman spectroscopy. Piezospectroscopic coefficients were determined for all compositions of ZrB2-SiC ceramic under study and their experimentally obtained values were compared with the piezospectroscopic coefficients both published in the literature and calculated using theoretical approach. Finally, the novel ZrB2-IrB2-SiC ceramic composites were also produced using Spark Plasma Sintering (SPS), where IrB2 powder was synthesized using mechanochemical route. It is expected that the IrB2 additive phase might contribute to the improved overall oxidation resistance of ZrB2 based ultra-high temperature ceramic composites.

This project was initiated by the Cardcrock Division of the Naval Surface Warfare Center (CDNSWC) and the Office of Naval Research to study the effects of various processing parameters on the residual stress state of HSLA-100 bead-on-plate weldments. Three groups of samples were provided to Virginia Tech by CDNSWC. The first (GPX) was a sample of unwelded, as-received base material; the second group (RS-) consisted of an experimental matrix of differently processed bead-on-plate weldments which were all ground prior to welding in order to prepare the surface for welding; the third group (SR-) was a pair of weldments vacuum annealed at 1200°F for one and two hours, and then welded (without grinding) using welding parameters identical to weldments from the second group. X-ray diffraction was used to measure the surface residual stress state of all samples. It was found that the surface residual stress states of the GPX plate and the unwelded SR-group plates showed no statistically significant difference in magnitude, though the variation of the stress state over the surface of the plates seemed to decrease with increasing annealing time. The severe, non-uniform grinding was determined to play a very large role in the residual stresses generated in the welds, sometimes changing both the magnitude and the shape of the stress patterns. Residual stresses in plates that were ground before welding were always more tensile than those that were not ground. Grinding also caused a large compressive-to-tensile stress gradient in the transverse direction. The grinding made it difficult to determine the effects of different welding parameters on the residual stress state. Assuming that the stresses closest to the weld bead are exclusively residual stresses due to welding, preheat temperature reduced the tensile nature, or increased the compressive nature, of the residual stresses. This is due to the preheat reducing the effect of shrinkage stresses induced after the austenite transformation upon cooling of the weldment. Because of the effects of grinding and the small sample sizes, no definitive conclusions could be drawn about the effects of heat input and plate thickness. It was shown that grinding was the dominant parameter on the residual stress state in these HSLA-100 bead-on-plate weldments. Because the angle and force of grinding are purely at the discretion of the operator, it is very difficult to determine the effects of different welding parameters on the residual stresses generated in bead-on-plate weldments ground prior to welding. / Master of Science