Cast iron, taking the advantages of the advanced castability forming components of complex geometries and favorable mechanical properties, is employed in engine components in truck industries. Compacted graphite iron (CGI) integrates both merits of lamellar graphite iron (LGI) and spheroidal graphite iron (SGI) such as good machinability and high thermal conductivity from LGI, high ultimate tensile strength (UTS), good fatigue resistance, high elastic modulus, and high ductility from SGI, thus is now becoming a competitive alternative of traditional LGI in cylinder blocks and heads. Due to the shape complexity of cast components, residual stresses arise accordingly. Normal methods for measuring stresses have various practical difficulties that affect accuracy. For example, in strain gauge measurements such as hole drilling and cutting, casting skins need to be polished as the attachment of strain gauge requires a smooth surface condition for precise detection, though any mechanical treatment would change the residual stress state. On the other hand, electropolishing applied in XRD measurement for extracting depth profile causes no release of stresses, nevertheless, there is no dissolution reaction on graphite particles. This would retard further polishing and form a rough surface instead of flat extraction. A visual strain detection system relies on a stable and clean surface condition, therefore, when it is combined with the drilling technique, the drilling chips could be a vital problem for repeatability when they block the view of drilling edges. Ultrasonic measurement, in theory, has lower precision by averaging the stresses within a certain volume beneath surfaces. A number of methods have been developed to measure residual stresses, ranging from destructive to non-destructive according to the removal amount of materials. In this thesis work, several measurement methods are implemented on cylinder heads and the results are compared with simulation to develop a suitable method of measuring residual stresses in cast engine components. It is found that longer shakeout time lowers the tensile stresses and develops more compressive stresses in the surface layer. Cutting is a suitable method compared with others. Incremental center-hole drilling technique is not suitable to measure cast components as the surface grinding before stain gauge mounting causes high deviation. Hole drilling with visual strain detection provided high errors within the first 0.1 mm as the strains were too weak to be visualized at the beginning of drilling. The electropolishing process was also found retarded by graphite particles, and the XRD results are more trustworthy with more tilt angles. Ultrasonic measurement is rather rough due to the influence of graphite on the traveling velocity of ultrasound. / Tack vare sin utmärkta gjutbarhet, som möjliggör gjutning av komplexa geometrier, samt goda mekaniska egenskaper är gjutjärn första valet i många motorkomponenter inom lastbilsindustrin. Kompaktgrafitjärn (CGI) kombinerar fördelarna med lamellärt grafitjärn (LGI) och sfäroidalt grafitjärn (SGI) såsom god bearbetbarhet och hög värmeledningsförmåga från LGI, hög draghållfasthet (UTS), hög utmattningshållfasthet, hög elastisk modul (E-modul) och hög duktilitet från SGI. Detta gör kompaktgrafitjärn till konkurrenskraftigt alternativ till traditionell LGI i cylinderblock och huvud. På grund av formkomplexiteten hos gjutkomponenter uppstår restspänningar. Normala metoder för att mäta spänningar har olika praktiska svårigheter som påverkar noggrannheten. Vid töjningsmätningar genom hålborrning och sågning måste t ex gjutskinn slipas bort eftersom fästning av töjningsmätare kräver en jämn yta för exakt detektion, även om prepareringen kan påverka spänningstillstånd. Å andra sidan orsakar elektropolering som appliceras i XRD-mätning för extrahering av djupprofil inte att spänningar frigörs, däremot finns det inget etsmedel för grafitpartiklar. Detta gör att poleringen skapar en ojämn yta istället för en platts yta. Systemet för visuell detektering av förlängning förlitar sig på en stabil och ren yta. Därför kan borrspånen, när visuell detektering kombineras med borrteknik, vara ett viktigt problem för repeterbarheten. Ultraljudsmätning har i teorin lägre precision genom att den endast mäter medelvärdet av spänningarna i en viss volym under ytan. Ett antal metoder har utvecklats för att mäta restspänningar, både förstörande och oförstörande. I denna examensarbetesrapport implementeras flera mätmetoder på motorcylinderhuvuden och resultaten jämförs med simulering för att utveckla en lämplig metod för att mäta restspänningar i gjutna motorkomponenter. Det visas i arbetet att längre urslagstid kan sänka dragspänningarna och utveckla mer tryckspänningar i ytskiktet. Sågning är en lämplig metod jämfört med de andra. Inkrementell hålborrningsteknik är inte lämplig för att mäta restspänningar på gjutkomponenter eftersom ytslipningen före montering av töjningsmätare orsakar hög avvikelse. Hålborrning med visuell töjningsdetektering gav höga fel inom den första 0,1 mm från ytan eftersom töjningen är för liten för att kunna visualiseras i början av borrningen. Det är hänt ofta att elektropoleringsprocessen före XRD-mätningen blir fördröjd av grafitpartiklar, och XRD-resultaten är mer pålitliga med fler lutningsvinklar. Ultraljudsmätning är grov på grund av grafitens påverkan på ultraljudets hastighet.

Lightweighting of automotive and heavy-duty vehicle components is an important task that does not need any further motivation or background. It can be read in a large part of the technical papers in the field. A common approach for finding lighter solutions is to increase the material grade while decreasing the material thickness. Often in combination with design changes. For perfectly smooth components this is not an issue, but when cut edges from manufacturing processes are present the situation changes. One topic to address is that increased material grade often means increased notch and surface damage sensitivity. This has implications both on forming and fatigue. The reason for selecting a higher strength material is to allow for higher stresses in design. It has however been shown that for a given stress level the fatigue performance of a higher strength material could be worse than for a lower strength counterpart if punched holes or trimmed edges are present. This means that in the search of lower weight there is a risk of increasing stresses, and at the same time selecting a material that is less suited to handle this increase. Hence, engineers and developers are put in a position where these effects must be quantified to find the most efficient solution. This quantification is a cumbersome and expensive task, often including a considerable amount of testing. Important sources of fatigue life reduction in this context are the residual stresses in the loading direction and the surface roughness in the cut edge. This thesis aims to present an overview of metal fatigue in the context of shear cut components. Necessary knowledge regarding the shear cutting process is provided along with a description of numerical methods and considerations for process simulations. These findings are then applied to the presented papers where the first introduces a simplified approach for numerical simulation of shear cutting to obtain residual stresses. In this approach the simplification mainly lies in the failure model calibration. The second paper studies the possibility of using the obtained residual stresses together with measured values of surface roughness to quantify fatigue life reduction of shear cut specimens.

Advances in computer automation and control, compact and portable x-ray sources, and reliable and efficient detector systems over the last ten years have allowed X-Ray Determination of Residual Stress (XRDRS) measurements to become a viable method of evaluating the state of stress in metals, alloys, and ceramics. However, problems associated with incorrect XRDRS equipment operation and poor experimental technique are prevalent, necessitating better operator training and education. Therefore, an interactive computer workstation, called RS/hyper, was developed to lead the operator towards correct operating procedures and reliable experimental technique. RS/hyper teaches the operator proper machine setup, machine maintenance, radiation safety, experimental technique, theoretical understanding, and provides limited data evaluation. Graphical aids are used extensively to avoid confusion and misinterpretation during the learning process. Since RS/hyper is interactive, the operator may select the desired level of understanding on a particular topic. These topics are linked, through a hypertext interface, so that the information is presented coherently and efficiently. Compared to written texts and references, RS/hyper has been shown in preliminary tests to reduce XRDRS training and problem solving time by a factor of 16. RS/hyper will train novice users of XRDRS equipment so that the data acquired from such machines will be reliable in an industrial environment. Since the software educates the user, the results of the data will be more accurately represented before interpretation. The experienced user should find RS/hyper useful as a reference of XRDRS and related information. / Master of Science

A series of experiments was performed in an attempt to measure the effects of surface residual stresses on the stress corrosion cracking/hydrogen embrittlement (SCC/HE) behavior of AISI 4340 steel. Stress corrosion tests were performed under load control on cylindrical and notched tensile specimens in acidified 3.5% NaCl solution. The electrochemical potential of the specimens was maintained at -0.7 V versus a saturated calomel reference electrode. Time to failure for specimens tested at various applied and residual stress levels was measured. Stress relieved specimens as well as specimens containing mechanically induced residual stresses were tested. Residual stresses were estimated using Neuber's rule and were measured using an x-ray diffraction technique. In all cases, the sum of the applied and residual stresses was greater than zero. Test results showed the initiation of SCC/HE cracks to be insensitive to the effects of surface residual stresses under the conditions evaluated. This is probably a result of the total time to failure criterion used to evaluate the SCC/HE tests. The extremely aggressive environment used in these experiments apparently led to rapid crack initiation, even in specimens containing compressive residual stresses. Another possible explanation of the insensitivity of this series of tests is crack initiation in the interior of the specimens below the depth of the mechanically induced residual stresses. / Master of Science

The research presented here investigates the effects of laser trimming on the state of stress in alumina Al₂O₃ hybrid microelectronics substrates. Evaluation of stress was performed using x-ray diffraction residual stress analysis and dynamic strain measurements using strain gages before and after laser trimming. X-ray diffraction measurements were carried out in both the longitudinal and transverse directions on the front and back sides of the substrates. The dynamic strain measurements were performed in situ with strain gages attached to the bottom of the substrates while the substrates were trimmed with a 400 watt YAG laser. The substrates were characterized using optical microscopy, scanning electron microscopy / energy dispersive x-ray analysis (SEM/EDAX), electron probe microanalysis (EPMA) and electron spectroscopy for chemical analysis (ESCA). The results from these characterization steps gave results for fractography (optical), surface and bulk composition (SEM/EDAX), chemical composition (ESCA) and phase analysis (EPMA). Results show that laser trimming produces stress gradients which are generally tensile in nature and could have deleterious effects on the mechanical integrity of the substrates if used in hybrid microelectronic applications. Furthermore the stress distribution across the substrates was found to be uniformly distributed showing no peak stresses near the heat affected zone (HAZ) boundary. Phase analysis determined that the substrates contained a magnesium aluminum spinel phase (MgAl₂O₄) and that the glass and pore phases are randomly distributed in the substrates. This could have some overall effect on the state of residual stress in the substrates after they have been laser trimmed. / Master of Science

The present doctoral thesis summarises results of investigation focused on the characterisation of materials involved in Solid Oxide Cell technology. The main topic of investigation was the ceramic cell, also known as MEA. Particular attention was given to the role that bi-material interfaces, co-sintering effects and residual stresses play in the resulting mechanical response. The first main goal was to investigate the effects of the manufacturing process (i.e. layer by layer deposition) on the mechanical response; to enable this investigation, electrode layers were screen-printed one by one on the electrolyte support and experimental tests were performed after every layer deposition. The experimental activity started with the measurement of the elastic characteristics. Both elastic and shear moduli were measured via three different techniques at room and high temperature. Then, uniaxial and biaxial flexural strengths were determined via two loading configurations. The analysis of the elastic and fracture behaviours of the MEA revealed that the addition of layers to the electrolyte has a detrimental effect on the final mechanical response. Elastic characteristics and flexural strength of the electrolyte on the MEA level are sensibly reduced. The reasons behind the weakening effect can be ascribed to the presence and redistribution of residual stresses, changes in the crack initiation site, porosity of layers and pre-cracks formation in the electrode layers. Finally, the coefficients of thermal expansion were evaluated via dilatometry on bulk materials serving as inputs for finite elements analyses supporting experiments and results interpretation. The second most important goal was to assess the influence of operating conditions on the integrity of the MEA. Here interactions of ceramic–metal interfaces within the repetition unit operating at high temperatures and as well at both oxidative and reductive atmospheres were investigated. The elastic and fracture responses of MEA extracted from SOC stacks after several hours of service were analysed. Layer delamination and loss of mechanical strength were observed with increasing operational time. Moreover, SEM observations helped to detect significant microstructural changes of the electrodes (e.g. demixing, coarsening, elemental migration and depletion), which might be responsible for decreased electrochemical performances. All the materials presented in this work are part of SOC stacks produced and commercialised by Sunfire GmbH, which is one of the world leading companies in the field.

Les alliages de titane sont largement utilisés dans le secteur de l’aéronautique. Cependant,ces alliages sont très sensibles aux gammes d’élaboration et de mises en forme. Cesdernières ont une grande influence sur l’intégrité de surface des produits finis, ce qui aun impact sur la durée de vie des pièces en service. Il est donc nécessaire de maîtriser lesprocédés afin de pouvoir définir la tenue en service des pièces.Dans ces travaux, les différentes intégrités de surface sont décrites en termes d’évolutionmicrostructurale, de contraintes résiduelles et de micro-géométrie. Des essais de fatigueen flexion 4 points sont réalisés pour tester les performances mécaniques de ces surfaces.Nous avons remarqué une bonne cohérence entre les modèles reliant l’intégrité de surfaceet la tenue en fatigue déterminée expérimentalement.De plus, étant donné que les alliages de titane ont des microstructures complexes etpeuvent être multiphasés, nous nous sommes aussi intéressés au caractère hétérogènede ces matériaux principalement dans l’analyse de contraintes résiduelles déterminées àl’aide de la diffraction des rayons X. Nous avons remarqué que ces hétérogénéités ontun impact sur la détermination des contraintes résiduelles. De fait une méthodologiede détermination de contraintes non standard a été mise en place et validée par dessimulations utilisant un modèle d’homogénéisation auto-cohérent.Ces modèles d’homogénéisation sont intéressants d’un point de vue de la déterminationdes contraintes résiduelles par diffraction des rayons X car ils permettent la prise encompte de l’aspect multiphasé des matériaux ainsi que leur caractère anisotrope. / Titanium alloys are widely used in aeronautics industries. However, these alloys are highlysensitive to the method for elaboration and transformation processes. These processesimpact on the surface integrity of products. Therefore, they have to be controlled inorder to predict life time of structures.In this work, the study of surface integrity is focused on the description of microstructalevolution, residual stresses and micro-geometry. Four points bending tests were performedin order to determined the fatigue limit of the different studied processes. We find outa good consistency between models used to determinate lifetime from surface integrityinvestigation and experimental results.Moreover, microstructures of titanium alloys are highly complex and they often are twophasedmaterials. Consequently, we studied the heterogeneous behaviour of such materialby X-ray diffraction investigation.We found out that these heterogeneities have an impacton residual stresses determination. Therefore, a non-standard methodology was definedand validate by simulation using a micro-mechanic model : a self-consistent model.Micro-mechanical models are interesting for the residual stresses determination using Xraydiffraction because they allow to take into account heterogeneous and anisotropicbehaviours through anisotropic elasticity and anisotropic texture.

A soldagem é o processo de união mais utilizado na fabricação de equipamentos pela indústria mecânica. Devido à introdução de calor durante o processo de soldagem, dependente do posicionamento da tocha e consequentemente do tempo, dilatações e contrações não uniformes produzem tensões térmicas no componente em questão, as quais permanecem como residuais ao final do processo, ao se atingir o equilíbrio térmico. O entendimento da formação e comportamento destas tensões se torna importante, pois na presença de carregamentos externos, a integridade estrutural do elemento mecânico pode ser comprometida. Portanto, este estudo visa analisar o comportamento destas tensões térmicas, avaliando ao final a magnitude e distribuição das tensões residuais, tendo como ferramenta o método dos elementos finitos. Inicialmente são apresentados os principais processos de soldagem envolvendo a fusão de materiais por meio de arco elétrico, sendo possível com base em uma explicação teórica, observar e entender a formação das tensões oriundas destes processos. Na sequência uma revisão bibliográfica contendo as principais técnicas para modelamento deste problema pelo método dos elementos finitos é apresentada, navegando por conceitos da análise térmica, que envolve o estudo das temperaturas e mecânica, a qual avalia as tensões formadas. Com toda parte teórica consolidada, um caso exemplo é analisado, simulando desta maneira um processo GTAW pelo programa computacional ANSYS, e comparando os resultados numéricos com os dados experimentais e numéricos obtidos na literatura. Ao final da simulação conclui-se que o modelo analisado reproduz fielmente a distribuição de temperaturas durante o processo e também estima corretamente as tensões residuais na chapa soldada, mostrando que a simulação de processos de soldagem utilizando o método dos elementos finitos se apresenta como uma ferramenta alternativa a indústria no aprimoramento de processos existentes ou desenvolvimento de novos. / Welding is the most used joining process in equipment manufacture by mechanical industry. Due to heat application during welding, varying with torch position and therefore by time, non-uniform expansion and contraction produces thermal stresses, which remains as residual when the component reaches thermal equilibrium. Formation and behavior of these stresses understanding becomes important since on external forces presence the mechanical piece may have it structural integrity compromised. This study aims to analyze thermal stress behavior due to welding evaluating residual stress magnitude and distribution at the process end by the finite element method. First of all fusion welding process by an electric arc are presented and a theoretical explanation about thermal stresses formation during welding is shared. Next is shown a bibliographic research with main techniques to model these problems using the finite element method, including thermal analysis, which involves temperature distribution study, and structural analysis that evaluate resulting stresses. With all theoretical background consolidated an example case of a GTAW process is studied utilizing ANSYS software, comparing numerical results with experimental and numerical data obtained in literature. It is possible to conclude that analyzed model accurately reproduces temperature distribution and also residual stress in the welded specimen proving that a welding process simulation via finite element method is an alternative tool for industry purposes on improving existing process and developing new ones.

[pt] Uma das técnicas mais aplicadas para medir tensões residuais em componentes mecânicos é a técnica do furo cego. Esta técnica é de fácil aplicação industrial e é normalizada pela ASTM E 837. Entretanto, devido à concentração de tensões gerada pelo furo, há restrições quanto à aplicação deste método quando as tensões residuais presentes excedem 0.3 da tensão de escoamento do material, Sy. Há na literatura trabalhos que avaliam, por elementos finitos, os erros gerados ao se aplicar diretamente estes coeficientes em componentes com altos níveis de tensões residuais. Em alguns casos, o erro pode chegar a 140%, para tensões da ordem de 0.9 de Sy. Porém, para retrocalcular as tensões residuais estes trabalhos também usam hipóteses válidas apenas no regime elástico, de forma que os resultados por eles apresentados podem ter imprecisões. Neste trabalho propõem-se novas metodologias numéricas para avaliar a validade da norma ASTM E 837 em regime plástico, através de uma modelagem mais realística do alívio de tensão gerado pela usinagem do furo, evitando o uso de hipóteses linear-elásticas. Estas metodologias são: Estado Equivalente, na qual uma tensão equivalente àquela agindo no componente é aplicada na borda do furo; metodologia Morte de Elementos na qual os elementos presentes na região em que o furo será usinado são eliminados numericamente em vários passos, de forma a simular o processo de usinagem; e a metodologia Tensão Substituta, na qual o material presente na região do furo é substituído pela tensão que nele age, a qual é retirada gradativamente. Foram modeladas em elementos finitos placas com furos passantes e cegos, submetidas a carregamentos uniaxiais e biaxiais, desde 0.3 Sy até 0.9 Sy. Além disso, foram utilizados nas simulações materiais tendo limite elástico e de escoamento coincidentes e não coincidentes. Os erros encontrados entre as tensões retrocalculadas e as tensões aplicadas, para todas as situações são menores que encontrados por outros pesquisadores, obtendo-se no pior caso 70 por cento. Finalmente, conclui-se que as metodologias Tensão Substituta e Morte de Elementos são as que simulam de forma mais próxima da realidade o processo de usinagem de um furo em um placa submetida à altas tensões. / [en] One of the most popular techniques applied to measure residual stresses is the hole-drilling technique. The technique is easy to be applied at industry, and is normalized ASTM E 837. However, due to the stress concentration caused by the machined hole, the technique can not be used if the residual stresses are higher than one third of the material yield strength, Sy. There are several researches articles that evaluate the errors aroused from the use of linear-elastic coefficients in case where plastic strains are present. In general, those articles apply the finite element to simulate the process of drilling the hole and stress relief. In certain case it is showed that the error can reach 140% of the applied stress. However,those articles use linear-elastics hypothesis and therefore their predictions can also include mistakes. The present work proposes new numerical methodologies to evaluate the usefulness of the hole- drilling technique, as it is described by the ASTM E 387, in the plastic range. The aim is to model the stress relief caused by the hole`s drilling process in a more realistic way, in order to avoid the use of linear-elastics hypothesis. The proposed methodologies are: Equivalent State, in which is applied in the hole a stress equivalent to that one acting externally on the component; Element Death, in which the drilling process is simulated by eliminating numerically in several steps the material which vanishes during the drilling process, and the Replacement Stress; in which the material in the hole is replaced by the stress that is acting at its walls. Those mentioned methodologies were implemented using a commercial finite element program which simulated plates with through the thickness and blind holes. Those plates have been loaded with three different loadings which varied from 0.3 to 0.9 Sy. Two materials with different stress-strain curves have been used. One of them had the elastic limit equal to the yield limit and the other one has those two limits different. In the worst case the errors found were 70 percent, which is smaller than those found by others researchers. It was concluded that, the Replacement Stress and the Elements Death methodologies are those that best simulate the process of drilling a hole in a plate which is under high stresses.

Objetivos: avaliar espécimes com as seguintes combinações de materiais/processamentos: a) porcelana feldspática aplicada por meio de técnica tradicional sobre infraestrutura de zircônia; b) porcelana feldspática injetada sobre infraestrutura de zircônia, c) porcelana feldspática usinada em sistema CAD-CAM e cimentada (Rapid Layer Technique) sobre infraestrutura de zircônia; d) vitro-cerâmica à base de dissilicato de lítio processada por meio de sistema CAD-CAM e unida à infraestrutura de zircônia por meio da sinterização de um vidro na interface (técnica CAD-on) com relação a: (1) resistência ao lascamento de aresta do material de recobrimento (a influência do tipo de resfriamento foi analisada para os processamentos a e b) e; (2) níveis de tensão residual superficial mensurados nos materiais de recobrimento, por meio de ensaio de fratura por endentação (a influência do tipo de resfriamento foi analisada para os processamentos a e b). Material e métodos: Barras de duas camadas com dimensões de 25 mm de comprimento por 4 mm de largura e com espessuras de porcelana e infraestrutura combinadas de modo a oferecer a razão de 1 mm de cada material foram confeccionadas seguindo as orientações dos fabricantes. O teste de lascamento de aresta foi realizado em uma máquina universal de ensaios, utilizando um endentador Vickers acoplado a essa máquina. A tensão térmica residual superficial foi calculada a partir de endentações feitas na camada de porcelana. Resultados: A resistência ao lascamento (ReA) foi significativamente maior para os espécimes processados pelo sistema CAD-on (ReA = 612,8±271,8 N/mm). Bilayers confeccionadas pelo sistema Rapid Layer Technique apresentaram valor de ReA intermediário de (417,9±187,2 N/mm) e os grupos nos quais foi utilizada porcelana processada pela técnica de sinterização tradicional ou por injeção foram os que apresentaram os menores valores de resistência ao lascamento, com médias de 349,7±116,8 N/mm (tradicional/resfriamento lento) 285,6±117,5 N/mm (tradicional/resfriamento rápido), 298,4±119,9 N/mm (injetado/resfriamento lento) e 263,5±107,9 N/mm (injetado/resfriamento rápido). Para os grupos com porcelana aplicada sobre a infraestrutura pela técnica tradicional e injetada o teste t de Student mostrou que houve um efeito significativo do protocolo de resfriamento, sendo que os espécimes que passaram por resfriamento lento atingiram maiores valores de ReA. Apenas o grupo Rapid Layer Technique apresentou média de tensão superficial correspondente a tensões de tração. Todos os outros grupos apresentaram tensões de compressão na superfície. Conclusões: há um efeito significativo da associação material/processamento na resistência ao lascamento de aresta das bilayers testadas e com relação ao efeito da velocidade de resfriamento (lento e rápido). Os espécimes que passaram por resfriamento lento atingiram maiores valores de resistência ao lascamento, independentemente do método de processamento (tradicional ou injeção). A combinação material/processamento afetou significativamente as tensões residuais superficiais das bilayers testadas, porém, não houve efeito da velocidade de resfriamento no nível de tensões térmicas residuais superficiais para os espécimes processados tanto pela técnica tradicional como pela técnica de injeção. / Objectives: to evaluate specimens with the following materials/processing combinations: a) feldspathic porcelain applied on zirconia through traditional technique; b) feldspathic porcelain applied on zirconia through press-on technique, c) feldspathic porcelain milled in CAD-CAM system and cemented (Rapid Layer Technique) on zirconia infrastructure; D) lithium disilicate glass-ceramic milled in CAD-CAM system and bonded to the zirconia infrastructure by means of a fusion glass-ceramic applied at the interface (CAD-on technique) relating to: (1) edge chipping resistance of the veneering materials (influence of the cooling rate was analyzed for the processing methods a and b) and; (2) surface residual stress levels measured in the veneering materials through indentation fracture method (influence of the cooling rate was analyzed for the processing methods a and b). Materials and methods: Bilayer bars with 25 mm length, 4 mm width and thicknesses of porcelain and infrastructure combined to provide 1 mm ratio of each material were made following manufacturers\' instructions. The edge chipping test was performed in an universal testing machine, using a Vickers indenter coupled to it. The surface residual thermal stress was calculated from indentations made on the porcelain layer. Results: The chipping resistance (ReA) was significantly higher for the specimens processed by the CAD-on system (ReA = 612.8±271.8 N/mm). Bilayers made by the Rapid Layer Technique system presented an intermediate ReA mean value of 417.9±187.2 N/mm and the groups in which the porcelain layer was processed by traditional or press-on technique presented the lowest values of chipping resistance, with mean values of 349,7±116,8 N/mm (traditional/slow cooling) 285,6±117,5 N/mm (traditional/fast cooling), 298,4±119,9 N/mm (press-on/slow cooling) and 263,5±107,9 N/mm (press-on/fast cooling). For the groups with porcelain applied on the infrastructure by the traditional and press-on technique, Student\'s t test showed that there was a significant effect of the cooling rate, and the specimens that went through slow cooling rate reached higher ReA values. Only the Rapid Layer Technique group presented mean of surface stresses corresponding to tensile stresses. All other groups exhibited surface compression stresses. Conclusions: there is a significant effect of the material/processing association on the edge chipping resistance of the tested bilayers and regarding the cooling rate effect (slow and fast), the specimens that went through slow cooling rate reached higher values of edge chipping resistance, regardless of the processing method (traditional or press-on). The material/processing combination significantly affected the surface residual stresses of the tested bilayers, however, there was no effect of the cooling rate on the superficial residual thermal stresses levels for the specimens processed by both the traditional technique and the press-on technique.