Thesis (Ph. D.)--Florida State University, 2005. / Advisor: Dr. Hamid Garmestani, Florida State University, College of Engineering, Department of Mechanical Engineering Title and description from dissertation home page (viewed June 14, 2005). Document formatted into pages; contains xv, 115 pages. Includes bibliographical references.

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A friction stir welding equipment with high rotation speed and constant load is successfully developed in this study to weld the multi-laminated silicon steel sheets widely used on regular transformers. This equipment consists of a spinning unit, a loading unit, and a feeding unit. A WC round rod with 3 mm diameter is used as welding tool. Under different operating conditions, such as the normal load(140~480 N), the spindle speed (12000~24000rpm), the feeding rate (0~1.58 mm/s), the welding characteristics and the welding mechanism of multi-laminated silicon steel sheets, and the welding feasibility of the transformer are investigated. Firstly, the contour map of welding depth in terms of spindle speed,normal load, and depth of point welding is established for dwell welding time 15 seconds. Secondly, based on this contour map, two experimental conditions of the long-pass welding tests are selected to investigate the effect of normal load (Fd), the spindle speed (Ns), and the feeding rate (f) on the failure load of weld under the shear. According to the experimental results, the empirical formula is obtained as Ff =40.6(Fd¡DNs)1.123(f)-0.791. In this formula,(Fd¡DNs)1.123(f)-0.791 is proportional to the frictional work per unit moving distance. With the larger frictional work, this represents the heat generation of the workpiece material is higher with more uniform friction stir, so that the bonding strength of the material increases and the failure load of weld is larger. According to the micrograph observations, the thermo-mechanically affected zone is significantly influenced by high heat action generated from the friction between the tool and the weld surface region, so that the plastic flow of the workpiece material occurs to cause the multi-laminated silicon steel sheets bonding together. Finally, the transformer is successfully welded under the experimental conditions of the long-pass welding tests with the smaller welding depth and the better failure load.

Les mécanismes d'oxydation, de décapage et sur-décapage d'un acier bas carbone est d'un acier fortement allié au silicium (1,6 et 3.2 % en masse de silicium) ont été étudiés. Le suivi de l'oxydation par thermogravimétrie et la caractérisation de la calamine des aciers fortement alliés au silicium a montré un effet très marquant de passivation de la couche de silice. Les calamines des échantillons modèles sont composées de couches d'hématite, magnétite et wüstite partiellement décomposée en fer et magnétite pour l'acier bas carbone. Pour l'acier au silicium, la fayalite est présente à l'interface acier/wüstite sous forme de grains ou d'une couche interne. Le suivi du potentiel de circuit ouvert pendant le décapage et sur-décapage de ces échantillons a montré un potentiel de corrosion stable et anodique pour les oxydes de fer et une chute drastique de ce potentiel au contact de l'acide avec le métal. Le suivi du taux de dissolution totale par ICP-AES combiné avec des mesures de courant de corrosion par la méthode de Tafel a montré une contribution importante de la dissolution électrochimique par oxydation de la wüstite et la magnétite et réduction de Fe3+ issu de la dissolution chimique de l'hématite et la magnétite. La fayalite est libérée dans la solution par dissolution de la wüstite ou du métal adjacents. Après le contact acide/metal, toutes les dissolutions sont exclusivement électrochimiques par corrosion du métal et réduction de la magnétite (cas des calamines industrielles). La spectroscopie d'impédance électrochimique a été utilisée pour la première fois pour ce type d'étude. L'estimation des valeurs de capacité a montré un comportement pseudo passif pour la couche d’hématite et d’électrode poreuse pour la wüstite. / Oxidation, pickling and over-pickling mechanisms of a low carbon steel and a high alloyed steel (1.6 and 3.2 wt.% Si) were investigated. The monitoring of oxidation with thermogravimetry and characterization of scale showed a very important passivating effect of the silica layer. Model scales are composed of layers of hematite, magnetite and partially decomposed wüstite into iron and magnetite for the low carbon steel. For the silicon steel, fayalite is present in the steel/wüstite interface as grains or an internal layer. Open circuit potential measurements during pickling and over-pickling of these samples showed a stable and anodic corrosion potential for iron oxides and a significant potential jump once the acid reaches the metal. The monitoring of the total dissolution rate with ICP-AES coupled with corrosion current measurements with the Tafel method showed an important contribution of electrochemical dissolution by oxidation of wüstite and magnetite and reduction of Fe+3 from chemical dissolution of hematite. Fayalite is liberated in the solution by dissolution of the surrounding wüstite or metal. After the contact acid/metal, all dissolutions are exclusively electrochemical by corrosion of the metal and reduction of magnetite (case for industrial scales). Electrochemical impedance spectroscopy was used for the first time for this kind of studies. The estimation of the capacitance values showed a passive like behaviour for hematite and a porous electrode one for wüstite.

Bolted cores made of coated silicon steel sheets constitute a vital part of heavy electrical equipment for transformers, motors and turbogenerators. Bolted laminates are eminently suitable for facilitating smooth magnetic flux paths, but, unfortunately, they are unable to suppress interlaminate shearing caused by flexural vibration generating noise levels often exceeding 100 dB during operation. The resulting din and cacophony in the surrounding has become a major environmental concern. This thesis makes an attempt to develop theoretical, experimental and numerical models for evolving an effective stiffness approach enhancing the design and analysis underlying nonlinear flexure of bolted laminates. While large machine cores contain thousands of thin sheets bolted together along with end plates, this thesis reports the results obtained on two different assemblies. Two 375 mm long 60 mm wide and 10 mm thick plates assembled with 3, 4 or 5 bolts constitute the first configuration. The second one which is much more realistic comprises 80 coated 270 micron silicon steel sheets with end plates of 2 or 4 mm thickness held together by 3 or 5 bolts. Static 3 point bend tests on these bolted assemblies are followed by instrumented impact tests. Static bending tests highlight the role of frictional nonlinearity inducing a drop in the stiffness due to sliding between the plates. An experimentally determined effective modulus in the initial linear range is utilized for static and dynamic finite element simulations. Nonlinear response of bolted plates is simulated using contact elements in between the sliding plates, plates and the bolts heads. Since the first fundamental mode of vibration dominates the tribomechanical vibration induced noise, the primary focus is on the fundamental frequency in bending. There is generally a good overall agreement in all the results obtained through theory, experiment and FE simulation. Experiments, however, unveil quite complex nonlinear effects induced by friction and plasticity outside the scope of this thesis. However, the low amplitude response of bolted laminates which is reasonably well captured in this thesis represents the starting point for initiating a more elaborate effort for addressing large amplitude nonlinear flexure in bolted laminates. These findings shed light on estimating and controlling noise and vibration levels in heavy electric machines.

Les travaux de recherche discutés dans ce manuscrit concernent la conception des générateurs de puissance électrique pour l'aéronautique. L’augmentation de la puissance massique de ces équipements passe par une augmentation des vitesses de rotation, donc une augmentation des contraintes. Un premier point est de s'assurer de la bonne tenue mécanique des matériaux. Un deuxième point est de pouvoir prendre en compte les modifications du comportement magnétique (et donc in fine du couple) lorsqu'ils sont soumis à un état de contraintes multiaxial. L’étude présentée vise en particulier à illustrer l’influence d'états de contraintes biaxiaux sur le comportement magnétique des matériaux constitutifs du rotor. Le défi repose sur la mise en place de méthodes de caractérisation du comportement magnéto-mécanique dissipatif uniaxial et multiaxial des nuances développées par Aperam et utilisées par Thales Avionics pour leurs applications aéronautiques (en FeCo-2V et Fe-3%Si à grains non orientés). Des essais non conventionnels seront effectués sur des échantillons en forme de croix de manière à s'approcher des contraintes réellement subies par le rotor. Les essais sont effectués sur la machine d'essai triaxiale Astrée du LMT-Cachan. L'état de contraintes est estimé par corrélation d'images et par diffraction des rayons X. Des mesures magnétiques anhystérétiques et de pertes d'énergie sous contraintes sont reportées. D'autre part, un modèle multi-échelle multiaxial, décrivant le comportement d’un VER à partir de l'équilibre énergétique à l'échelle microscopique sera présenté. L’approche est fondée sur la comparaison des énergies libres de chaque domaine. Une comparaison probabiliste est faite pour déterminer les variables internes que sont les fractions volumiques des domaines. Différentes stratégies envisageables pour modéliser la dissipation statique seront discutées. Puis nous présentons l’approche magnéto-élastique que nous avons retenue visant à une meilleure considération de l’effet de la contrainte sur le comportement des matériaux ferromagnétiques. / The research presented in this thesis is motivated by the design of rotors for high speed rotating machines. The increased power density of these devices requires a higher rotation speed, leading to higher levels of centrifugal forces and stress in the rotor. A first point is to ensure good mechanical strength of the materials. A second point is to take into account changes in the magnetic behavior (and ultimately torque) when they are subjected to a multiaxial stress state. The present study aims at exploring the influence of biaxial stress states on the magnetic behavior of the materials of the rotor. The challenge lies in the development of methods for the characterization of the magneto-mechanical dissipative uniaxial and multiaxial behavior of metal sheets developed by Aperam Alloy and used by Thales Avionics for their aeronautical applications (in FeCo-2V and non-oriented Fe-3%Si). Non conventional experiments are performed on cross-shaped samples in order to apply biaxial stress representative of the loadings experienced by rotors of rotating machines. These experiments are performed on a multiaxial testing machine, Astrée. Stress level is estimated thanks to digital image correlation and X-ray diffraction Both anhysteretic and dissipative magnetic responses to magneto-mechanical loadings have been recorded. On the other hand, a multi-scale multiaxial model describing the behavior of a RVE from the energy balance at the microscopic scale is presented. The approach is based on a comparison of the free energy of each domain. A probabilistic comparison is made to determine the volume fraction of domains used as internal variables. Different strategies for modeling the static dissipation are discussed. Then we present the chosen magneto-elastic approach, improving the description of the effect of stress on ferromagnetic materials behavior.

近年、自動車の電動化が加速しており、車両駆動を担うモータのさらなる効率向上が求められている。高効率モータ設計に向けて、主な損失の１つである鉄損予測の精度向上が求められている。本論文では、鉄損を構成する各種損失の中から、実用的なモデル化手法が確立していない、異常渦電流損に関して、磁気測定から影響を与える諸因子を検討した。また、得られた知見に基づき、モータ鉄損予測にあたり、実用的なモデルを開発した。 / In recent years, electrification of automobiles has accelerated, and further improvement in efficiency of motors that drive the vehicles is required. For high-efficiency motor design, it is important to improve the accuracy of iron loss estimation, which is one of the main losses in the motor. In this paper, we investigated influencing factors of excess loss, which is one element that consists iron loss and has not been established as practical estimating modeling, from the magnetic measurement. In addition, based on the obtained knowledge, a practical model was developed for motor iron loss estimation. / 博士(工学) / Doctor of Philosophy in Engineering / 同志社大学 / Doshisha University