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Le roulement est l'un des composants les plus importants des machines tournantes. Néanmoins, dans des conditions normales d'utilisation, il est soumis à de la fatigue de roulement qui peut conduire à un défaut d'écaillage. Dans ce travail, nous présentons un suivi de la fatigue d'un roulement de butée grâce à un banc d'essais dédié. L'analyse vibratoire est une méthode qui permet de caractériser et de localiser les défauts dans les roulements. Des mesures successives de ces niveaux de vibrations donnent des indications quant à l'évolution de la sévérité des défauts. Le suivi de cette évolution est fait grâce à un indicateur statistique, la valeur RMS (Root Mean Square) qui peut être corrélée avec la taille d'un écaillage de roulement. L'approche suit le fonctionnement du roulement de butée jusqu'à la dégradation avec une acquisition on line des états vibratoires sous forme de signaux temporels. A l'aide du traitement de signal, on obtient les valeurs des amplitudes vibratoires qui caractérisent l'état vibratoire du roulement. Par conséquent, ces valeurs nous permettent de tracer les courbes de fatigue. Au cours de notre travail expérimental, cette opération est appliquée à un lot de butées à billes pour lesquelles nous avons obtenu des courbes semblables où la tendance de l'évolution suit un modèle mathématique à partir de la détection de l'apparition de la première écaille. Le résultat de ce travail contribuera à prédire la durée de vie résiduelle avant la panne. / The bearing is one of the most important components of rotating machines. Nevertheless, in normal conditions of use, it is subject to fatigue which creates a defect called a rolling fatigue spalling. In this work, we present a follow-up of the thrust bearing fatigue on a test bench. Vibration analysis is a method used to characterize the defect. In order to obtain the fatigue curve more adjusted, we have studied the vibration level according to statistical indicators: the Root Mean Square value (RMS value), which is one of the best indicators to show the evolution of the bearing degradation. The approach follows the working of the bearing until the degradation with an on line acquisition of vibration statements in form of time signals. With the signal treatment, we obtain the values of the vibration amplitudes which characterize the vibration state of the bearing. Consequently, these values allow us to plot the fatigue curves. During our experimental work, this operation is applied for a batch of thrust bearings for which we have obtained similar fatigue curves where the evolution trend follows a mathematical model from the detection of the onset of the first spall. The result of this work will contribute to predict the working residual time before failure.

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Surfaces subjected to rolling and sliding contacts maysuffer from contact fatigue. This thesisdeals with solidmechanic aspects of contact fatigue including the descriptionand verificationof explaining mechanisms. The new mechanism forsurface initiated contact fatigue is basedon tensile surfacestresses from local asperity contacts. It is also realised thatsub-surfaceinitiated contact fatigue is the result of tensileresidual stresses that emanate from plasticdeformation belowthe surface. These mechanisms clearly show that contact fatiguecracksfollow the same rules as ordinary fatigue cracks inhardened steel. The thesis contains four papers that treat a new testprocedure named Standing ContactFatigue (SCF). The results ofthe test procedure have played an important role inthedevelopment and verification of the mechanisms for surfaceand sub-surface contact fatigue. The first part of the research work was experimental. Inthis part the SCF test properties wasdecided, crack resultsconfirmed and crack detection methods developed. Herecomparativestudies were performed using some differentmaterials and mechanical properties. It wasverified that SCFcould detect differences in contact fatigue resistance. Next a finite element model of the SCF test was evaluatedthrough the general-purposeprogram MARC. The model includedgraded material properties that originate from heattreatment.The residual surface deformation and surface compliance wereverified againstexperimental results. Crack initiation wasinvestigated in two ways. Firstly, the principalstresses atcritical locations were computed and plotted in a Haighdiagram. The diagramshowed that the cracks initiate in adirection perpendicular to the principal stress with thelargeststress range provided that the principal stress is tensilesometime during the load cycle. Secondly, some high cycle multiaxial fatigue criteria,including the Haigh principal stresscriterion, was evaluatedagainst the SCF crack initiation results. The surface cracklocation waspredicted by including statistical effects using aweakest-link criterion and a three-parameterWeibulldistribution. The SCF crack propagation was investigated by numericalevaluation ofJ1 andJ2integrals. The crack initiation and propagationphases were separated with a threshold criterionand a directioncriterion. It was found that during crack propagation bothsurface andsub-surface contact fatigue cracks follow thedirection with minimum mode II loading. Key words: contact fatigue mechanism; spall; spalling;surface crack; sub-surface crack;elasto-plastic indentation;contact compliance measurement; mixed-mode fatigue;fatiguecrack growth;J-integral; multiaxial fatigue; weakest-link. / QC 20100407

For roughly fifteen years the military has sought to use the properties of ceramics for armor applications. Current high-performance ceramics have extremely high compressive strengths and low densities. One ceramic that has been shown to be highly resistant under ballistic impact is silicon carbide (SiC). It has been found that even within the silicon carbides, those manufactured by certain methods and those with certain microstructural properties have advantages over others. In order to understand the microstructural reasons behind variations in ballistic properties, plate impact tests were conducted on two sintered silicon carbides with slightly different microstructures. Two variations of a silicon carbide with the trade name Hexoloy SA were obtained through Saint Gobain. Regular Hexoloy (RH) and Enhanced Hexoloy (EH) are pressureless sintered products having exactly the same chemistries. EH went through additional powder processing prior to sintering, producing a final product with a slightly different morphology than RH. Samples of each were characterized microstructurally including morphology, density, elastic wavespeeds, microhardness, fracture toughness, and flexure strength. The characterization revealed differences in porosity distribution and flexure strength. It was determined that the porosity distribution in EH had fewer large pores leading to an 18% increase in flexural strength over that for RH. The focus of the mechanics of materials community concerning dynamic material behavior is to pin down what exactly is happening microstructurally during ballistic events. Several studies have been conducted where material properties of one ceramic type are varied and the dynamic behavior is tested and analyzed. Usually, from one variation to the next, several properties are different making it hard to isolate the effect of each. For this study, the only difference in the materials was porosity distribution. Plate impact experiments were conducted at the Army Research Laboratory (ARL) using the gas gun facilities within the Impact Physics Branch. A VISAR was utilized to measure free surface velocities. Tests were performed on each material to determine the Hugoniot Elastic Limit (HEL) and spall strength. Spall strength was measured as a function of impact stress, and pulse duration.

abstract: Shock loading is a complex phenomenon that can lead to failure mechanisms such as strain localization, void nucleation and growth, and eventually spall fracture. The length scale of damage with respect to that of the surrounding microstructure has proven to be a key aspect in determining sites of failure initiation. Studying incipient stages of spall damage is of paramount importance to accurately determine initiation sites in the material microstructure where damage will nucleate and grow and to formulate continuum models that account for the variability of the damage process due to microstructural heterogeneity, which is the focus of this research. Shock loading experiments were conducted via flyer-plate impact tests for pressures of 2-6 GPa and strain rates of 105/s on copper polycrystals of varying thermomechanical processing conditions. Serial cross sectioning of recovered target disks was performed along with electron microscopy, electron backscattering diffraction (EBSD), focused ion beam (FIB) milling, and 3-D X-ray tomogrpahy (XRT) to gain 2-D and 3-D information on the spall plane and surrounding microstructure. Statistics on grain boundaries (GB) containing damage were obtained from 2-D data and GBs of misorientations 25° and 50° were found to have the highest probability to contain damage in as-received (AR), heat treated (HT), and fully recrystallized (FR) microstructures, while {111} Σ3 GBs were globally strong. The AR microstructure’s probability peak was the most pronounced indicating GB strength is the dominant factor for damage nucleation. 3-D XRT data was used to digitally render the spall planes of the AR, HT, and FR microstructures. From shape fitting the voids to ellipsoids, it was found that the AR microstructure contained greater than 55% intergranular damage, whereas the HT and FR microstructures contained predominantly transgranular and coalesced damage modes, respectively. 3-D reconstructions of large volume damage sites in shocked Cu multicrystals showed preference for damage nucleation at GBs between adjacent grains of a high Taylor factor mismatches as well as an angle between the shock direction and the GB physical normal of ~30°-45°. 3-D FIB sectioning of individual voids led to the discovery of uniform plastic zones ~25-50% the size of the void diameter and plastic deformation directions were characterized via local average misorientation maps. Incipient transgranular voids revealed from the sectioning process were present in grains of high Taylor factors along the shock direction, which is expected as materials with a low Taylor factor along the shock direction are susceptible to growth due their accomodation of plastic deformation. Fabrication of square waves using photolithography and chemical etching was developed to study the nature of plasticity at GBs away from the spall plane. Grains oriented close to <0 1 1> had half the residual amplitudes than grains oriented close to <0 0 1>. / Dissertation/Thesis / Doctoral Dissertation Mechanical Engineering 2015

Dynamic tensile characterization of geo-materials is critical to the modeling and design of protective structures that are often made of concrete. One of the most commonly used techniques currently associated with this type of testing is performed with a Kolsky bar and is known as the spall technique. The validity of the data from the spall technique is highly debated because the necessary boundary conditions for the experiment are not satisfied. By using a technique called pulse shaping, a new “controlled” spall technique was developed to satisfy all boundary conditions so that the analyzed data may be useful in modeling and design. The results from this project were promising and show the potential to revolutionize the way Kolsky bar testing is performed.

<p>  </p> <p>This work explored the dynamic behavior and failure mechanisms of an additively manufactured high-entropy alloy (HEA) when subjected to high-strain rate shock impacts. A laser-induced projectile impact testing (LIPIT) setup was used to study the dynamic behavior of the Cantor alloy CoCrFeMnNi samples manufactured using a directed-energy deposition technique. HEA flyers were accelerated by a pulse laser to velocities up to 1 km/s prior to impact with lithium fluoride glass windows. A photon Doppler velocimetry (PDV) system recorded the velocity of the flyer during the acceleration and subsequent impact. From this velocity profile, the Hugoniot coefficient and sound speed of the HEA samples were determined.</p> <p><br></p> <p>Upon determination of key shock parameters, spallation occurring due to shock was analyzed. Using the same LIPIT and PDV systems as the earlier testing, aluminum flyers of various thicknesses were accelerated into HEA samples. The back-surface velocity profiles of the HEA samples showed a characteristic “pullback” caused by the interaction of the tensile stress waves indicative of spall occurrence in the material. The magnitude of this pullback and the material properties determined in the first experiments allow for the measurement of spall strength at various strain-rates. This data is compared to previous data looking at similar HEAs manufactured using traditional methods. A comparison of this data showed that the spall strength of the HEA samples was equivalent to that of similar alloys but at significantly higher strain rates. As an increased strain-rate tends to result in increased spall strengths, further examination was needed to determine the reasons for this decreased spall strength in the AM samples.</p> <p><br></p> <p>Post-shock specimen recovery allowed for the failure mechanisms behind the spallation to be observed. Scanning electron microscope (SEM) images of the cross-section of the samples showed ductile fracture and void growth outside of the predicted spall region. Further imaging using energy dispersive spectroscopy (EDS) showed the presence of potentially chromium-oxide deposits in regions outside of the predicted spall plane. It is hypothesized that these regions created nucleation points about which spallation occurred. Thus, to achieve spall strength in AM HEAs equivalent to strengths in traditionally-casted alloys, the AM sample must be refined to reduce the occurrence of these deposits and voids.  </p>

Corrosion damage reduces the load-carrying capacity of bridges which poses a threat to passenger safety. The objective of this research was to reduce the resources involved in conventional bridge inspections which are an important tool in the condition assessment of bridges and to help in determining if live load testing is necessary. This research proposes a framework to link semi-automated damage detection on prestressed concrete bridge girders with the estimation of their residual flexural capacity. The framework was implemented on four full-scale corrosion damaged girders from decommissioned bridges in Virginia. 3D point clouds of the girders reconstructed from images using Structure from Motion (SfM) approach were textured with images containing cracks detected at pixel level using a U-Net (Fully Convolutional Network). Spalls were detected by identifying the locations where normals associated with the points in the 3D point cloud deviated from being perpendicular to the reference directions chosen, by an amount greater than a threshold angle. 3D textured mesh models, overlaid with the detected cracks and spalls were used as 3D damage maps to determine reduced cross-sectional areas of prestressing strands to account for the corrosion damage as per the recommendations of Naito, Jones, and Hodgson (2011). Scaling them to real-world dimensions enabled the measurement of any required dimension, eliminating the need for physical contact. The flexural capacities of a box beam and an I-beam estimated using strain compatibility analysis were validated with the actual capacities at failure sections determined from four destructive tests conducted by Al Rufaydah (2020). Along with the reduction in the cross-sectional areas of strands, limiting the ultimate strain that heavily corroded strands can develop was explored as a possible way to improve the results of the analysis. Strain compatibility analysis was used to estimate the ultimate rupture strain, in the heavily corroded bottommost layer prestressing strands exposed before the box beam was tested. More research is required to associate each level of strand corrosion with an average ultimate strain at which the corroded strands rupture. This framework was found to give satisfactory estimates of the residual strength. Reduction in resources involved in current visual inspection practices and eliminating the need for physical access, make this approach worthwhile to be explored further to improve the output of each step in the proposed framework. / Master of Science / Corrosion damage is a major concern for bridges as it reduces their load carrying capacity. Bridge failures in the past have been attributed to corrosion damage. The risk associated with corrosion damage caused failures increases as the infrastructure ages. Many bridges across the world built forty to fifty years ago are now in a deteriorated condition and need to be repaired and retrofitted. Visual inspections to identify damage or deterioration on a bridge are very important to assess the condition of the bridge and determine the need for repairing or for posting weight restrictions for the vehicles that use the bridge. These inspections require close physical access to the hard-to-reach areas of the bridge for physically measuring the damage which involves many resources in the form of experienced engineers, skilled labor, equipment, time, and money. The safety of the personnel involved in the inspections is also a major concern. Nowadays, a lot of research is being done in using Unmanned Aerial Vehicles (UAVs) like drones for bridge inspections and in using artificial intelligence for the detection of cracks on the images of concrete and steel members. Girders or beams in a bridge are the primary longitudinal load carrying members. Concrete inherently is weak in tension. To address this problem, High Strength steel reinforcement (called prestressing steel or prestressing strands) in prestressed concrete beams is pre-loaded with a tensile force before the application of any loads so that the regions which will experience tension under the service loads would be subjected to a pre-compression to improve the performance of the beam and delay cracking. Spalls are a type of corrosion damage on concrete members where portions of concrete fall off (section loss) due to corrosion in the steel reinforcement, exposing the reinforcement to the environment which leads to accelerated corrosion causing a loss of cross-sectional area and ultimately, a rupture in the steel. If the process of detecting the damage (cracks, spalls, exposed or severed reinforcement, etc.) is automated, the next logical step that would add great value would be, to quantify the effect of the damage detected on the load carrying capacity of the bridges. Using a quantified estimate of the remaining capacity of a bridge, determined after accounting for the corrosion damage, informed decisions can be made about the measures to be taken. This research proposes a stepwise framework to forge a link between a semi-automated visual inspection and residual capacity evaluation of actual prestressed concrete bridge girders obtained from two bridges that have been removed from service in Virginia due to extensive deterioration. 3D point clouds represent an object as a set of points on its surface in three dimensional space. These point clouds can be constructed either using laser scanning or using Photogrammetry from images of the girders captured with a digital camera. In this research, 3D point clouds are reconstructed from sequences of overlapping images of the girders using an approach called Structure from Motion (SfM) which locates matched pixels present between consecutive images in the 3D space. Crack-like features were automatically detected and highlighted on the images of the girders that were used to build the 3D point clouds using artificial intelligence (Neural Network). The images with cracks highlighted were applied as texture to the surface mesh on the point cloud to transfer the detail, color, and realism present in the images to the 3D model. Spalls were detected on 3D point clouds based on the orientation of the normals associated with the points with respect to the reference directions. Point clouds and textured meshes of the girders were scaled to real-world dimensions facilitating the measurement of any required dimension on the point clouds, eliminating the need for physical contact in condition assessment. Any cracks or spalls that went unidentified in the damage detection were visible on the textured meshes of the girders improving the performance of the approach. 3D textured mesh models of the girders overlaid with the detected cracks and spalls were used as 3D damage maps in residual strength estimation. Cross-sectional slices were extracted from the dense point clouds at various sections along the length of each girder. The slices were overlaid on the cross-section drawings of the girders, and the prestressing strands affected due to the corrosion damage were identified. They were reduced in cross-sectional area to account for the corrosion damage as per the recommendations of Naito, Jones, and Hodgson (2011) and were used in the calculation of the ultimate moment capacity of the girders using an approach called strain compatibility analysis. Estimated residual capacities were compared to the actual capacities of the girders found from destructive tests conducted by Al Rufaydah (2020). Comparisons are presented for the failure sections in these tests and the results were analyzed to evaluate the effectiveness of this framework. More research is to be done to determine the factors causing rupture in prestressing strands with different degrees of corrosion. This framework was found to give satisfactory estimates of the residual strength. Reduction in resources involved in current visual inspection practices and eliminating the need for physical access, make this approach worthwhile to be explored further to improve the output of each step in the proposed framework.