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Cold spray is a unique additive manufacturing process, where a large number of ductile metal micro particles are deposited to create new surface coatings or free-standing structures. Metallic particles are accelerated through a gas stream, reaching velocities of over 1 km/s. Accelerated particles experience a high-strain-rate microscopic ballistic collisions against a target substrate. Large amounts of kinetic energy results in extreme plastic deformation of the particles and substrate. Though the cold spray process has been in use for decades, the extreme material science behind the deformation of particles has not been well understood due to experimental difficulties arising from the succinct spatial (10 μm) and temporal scales (10 ns). In this study, using a recently developed micro-ballistic method, the advanced laser induced projectile impact test (α-LIPIT), the dynamic behavior of micro-particles during the collision is precisely defined. We observe single aluminum 6061 alloy particles, approximately 20μm in diameter, impact and rebound off of a rigid target surface over a broad range of impact speeds, temperatures, and substrate oxide film thicknesses. Through observation of the collisions, we extract characteristic information of the dynamic response of particles as well as the relationship with various parameters (e.g. surrounding temperature, particle diameter, oxide thickness, and impact velocity). By impacting a polished aluminum 6061 alloy substrate we are able to mimic the collision events that occur during cold spray deposition. The connection between the temperature increase and the oxide thickness plays a role in theorizing the cause of unexpected phenomena, such as increased rebound energies at higher temperatures. Highly-controlled single particle impacts results, are provided to calibrate and improve computational simulations as well. This, in turn, can provide insight into the underlying material science behind the cold spray process.

A traumatic brain injury is usually caused by a direct impact to the head and is a common cause of disability and death all around the world. The most effective method to predict brain injury today, is to use a finite element head model. In this investigation, the three injury predictors strain, strain rate, and the product of strain and strain rate were investigated using a rat brain finite element model. The main goal was to find which injury predictor most effectively would predict injury. To find the injury predictor with the highest area under curve value, comparisons between experimental results obtained from simulations and results from previously performed experiments on rats were made. To better understand how different factors can affect the severity of symptoms from a traumatic brain injury, a parametric study with a focus on rotational direction and rotational duration was conducted. Simulations were run on a rat brain finite element model for three rotational directions and three rotational durations.  The statistical analysis was completed for six experiments and nine brain regions. The three injury predictors were extracted from 26 simulations completed on a rat brain finite element model, and the maximum values of the 95th percentile for each brain region were extracted. The results showed that the product of the strain and the strain rate was the most effective injury predictor for four out of six experiments (unconscious time, EPM arm change, EPM open duration, and MWM session 3). The parametric study investigated rotation in the axial, coronal, and sagittal plane against the three rotational durations 1.5 ms, 3 ms, and 6 ms. The parametric study revealed that both the direction and duration of rotation importantly influence the extent of damage in traumatic brain injuries. The results showed that rotation in the axial plane and a 3 ms duration caused the most brain damage. It was also concluded that the results need to undergo additional verification to further define the relationships between the rotational direction, the rotational duration, and the injury predictors. / En traumatisk hjärnskada orsakas vanligtvis av våld mot huvudet och är en vanlig orsak till både funktionsnedsättningar och dödsfall världen över. Den effektivastemetoden för att kunna förutsäga en hjärnskada idag är att använda en finit elementmetodmodell av en hjärna.  I denna undersökning har de tre skadeprediktorerna belastning, belastningshastighet och produkten av belastningen och belastningshastigheten undersöktes med hjälp av simuleringar genomförda på en modell av en råtthjärna, byggd med hjälp av finita elementmetoden. Målet var att ta reda på vilken skadeprediktor som mest effektivt kunde förutsäga hjärnskada. För att hitta skadeprediktorn med högst area under curve-värde gjordes jämförelser mellan experimentella resultat från simuleringar mot resultat från tidigare utförda experiment på råttor. För att få en djupare förståelse för vilka parametrar som kan påverka graden av symptom från en traumatisk hjärnskada genomfördes en parametrisk studie med fokus på rotationsriktning och rotationstid. Nya simuleringar genomfördes på en finit elementmodell av en råtthjärna i tre rotationsriktningar och under tre rotationstider.  Den statistiska analysen utfördes på sex experiment och för nio regioner i hjärnan. Belastningen, belastningshastigheten samt produkten av belastningen och belastningshastigheten extraherades från 26 simulerade finita element råtthjärnor och maximumvärdet från den 95.e percentilen sparades. Resultatet av den statistiska analysen visade att produkten av belastningen och belastningshastigheten var den skadeprediktorn med bäst skadeförutsägelse för fyra av sex experiment(medvetslös tid, EPM arm förflyttning, EPM varaktighet i öppet utrymme och MWM session 3). Under den parametriska studien undersöktes axial, koronal och sagittal rotationsriktning mot de tre rotationstiderna 1.5 ms, 3 ms och 6 ms. Resultatet av den parametriska studien visade att både rotationsriktning och rotationstid spelar viktiga roller när det kommer till omfattningen av symptom som kan uppstå vid en traumatisk hjärnskada. För de undersökta delarna av hjärnan var den rotationsriktning som orsakade störst skada rotation i det axiala planet och den rotationstid som orsakade mest skada var vid 3 ms. Slutsatsen att resultatet bör genomgå ytterligare verifiering drogs. Detta för att ytterligare definiera sambanden mellan rotationsriktning, rotationstid och skadeprediktorerna.

Titanium (Ti) foams of different densities 1622-4100 Kgm-3 made by a powder sintering technique were studied as to their structural and mechanical properties. The foams were tested under static and dynamic loading. The material was tested quasi statically and dynamically under strain rates in the range of 0.001-2500 s-1 and under different loading modes. It was found that strain rate sensitivity is more pronounced in lower density foams. Experiments were complimented by virtual testing. Based on the Voronoi tessellations a computational method was developed to generate stochastic foam geometries. Statistical control was applied to produce geometries with the microstructural characteristics of the tested material. The generated structures were numerically tested under different loading modes and strain rates. Voronoi polyhedrals were used to form the porosity network of the open cell foams. The virtually generated foams replicated the geometrical features of the experimentally tested material. Meshes for finite element simulations were produced. Existing material models were used for the parent material behaviour (sintered Ti) and calibrated to experiments. The virtual foam geometries of different densities were numerically tested quasi statically under uniaxial, biaxial and triaxial loading modes in order to investigate their macroscopic behaviour. Dynamic loading was also applied for compression. Strain rate sensitive and insensitive models were used for the parent material model in order to examine the influence of geometry and material strain rate sensitivity under high rates of deformation. It was found that inertial effects can enhance the strain rate sensitivity for low density foams and numerical predictions for the generated foam geometries were in very good agreement with experimental results. Power laws were established in scaling material properties with density. The study includes: 1. Information on the material behaviour and data for macroscopically modelling this type of foams for a range of densities and under different strain rates. 2. A proposed method for virtually generating foam geometries at a microscopic scale and examine the effect of geometrical characteristics on the macroscopic behaviour of foams.

This work presents a systematic study of the mechanochemical processes leading to chemical reactions occurring due to effects of high-strain-rate deformation associated with uniaxial strain and uniaxial stress impact loading in highly heterogeneous metal powder-based reactive materials, specifically compacted mixtures of Ti/Al/B powders. This system was selected because of the large exothermic heat of reaction in the Ti+2B reaction, which can support the subsequent Al-combustion reaction. The unique deformation state achievable by such high-pressure loading methods can drive chemical reactions, mediated by microstructure-dependent meso-scale phenomena. Design of the next generation of multifunctional energetic structural materials (MESMs) consisting of metal-metal mixtures requires an understanding of the mechanochemical processes leading to chemical reactions under dynamic loading to properly engineer the materials. The highly heterogeneous and hierarchical microstructures inherent in compacted powder mixtures further complicate understanding of the mechanochemical origins of shock-induced reaction events due to the disparate length and time scales involved. A two-pronged approach is taken where impact experiments in both the uniaxial stress (rod-on-anvil Taylor impact experiments) and uniaxial strain (instrumented parallel-plate gas-gun experiments) load configurations are performed in conjunction with highly-resolved microstructure-based simulations replicating the experimental setup. The simulations capture the bulk response of the powder to the loading, and provide a look at the meso-scale deformation features observed under conditions of uniaxial stress or strain. Experiments under uniaxial stress loading reveal an optimal stoichiometry for Ti+2B mixtures containing up to 50% Al by volume, based on a reduced impact velocity threshold required for impact-induced reaction initiation as evidenced by observation of light emission. Uniaxial strain experiments on the Ti+2B binary mixture show possible expanded states in the powder at pressures greater than 6 GPa, consistent with the Ballotechnic hypothesis for shock-induced chemical reactions. Rise-time dispersive signatures are consistently observed under uniaxial strain loading, indicating complex compaction phenomena, which are reproducible by the meso-scale simulations. The simulations show the prevalence of shear banding and particle agglomeration in the uniaxial stress case, providing a possible rationale for the lower observed reaction threshold. Bulk shock response is captured by the uniaxial strain meso-scale simulations and is compared with PVDF stress gauge and VISAR traces to validate the simulation scheme. The simulations also reveal the meso-mechanical origins of the wave dispersion experimentally recorded by PVDF stress gauges.

Materials intended for disposal of spent nuclear fuel require a particular combination of physical and chemical properties. The driving forces and mechanisms underlying the material’s behavior must be scientifically understood in order to enable modeling at the relevant time- and length-scales. The processes that determine the mechanical behavior of copper canisters and iron inserts, as well as the evolution of their mechanical properties, are strongly dependent on the properties of various defects in the bulk copper and iron alloys. The first part of the present thesis deals with precipitation in the cast iron insert. A nodular cast iron insert will be used as the inner container of the spent nuclear fuel. Precipitation is investigated by computing effective interaction energies for point defect pairs (solute–solute and vacancy–solute) in bcc iron using first-principles calculations. The main considered impurities in the iron matrix include 3sp (Si, P, S) and 3d (Cr, Mn, Ni, Cu) solute elements. By computing interaction energies possibility of formation of different second phase particles such as late blooming phases (LBPs) in the cast iron insert is evaluated. The second part is devoted to the fundamentals of dislocations and their role in plastic deformation of metals. Deformation of single-crystal copper under high strain rates is simulated by employing dislocation dynamics (DD) method to examine the effect of strain rate on mechanical properties as well as dislocation microstructure development. Creep deformation of copper canister at low temperatures is studied. The copper canister will be used in the long-term storage of spent nuclear fuel as the outer shell of the waste package to provide corrosion protection. A glide rate is derived based on the assumption that at low temperatures it is controlled by the climb rate of jogs on the dislocations. Using DD simulation creep deformation of copper at low temperatures is modeled by taking glide but not climb into account. Moreover, effective stresses acting on dislocations are computed using the data extracted from DD simulations. / <p>QC 20170428</p>

The research presented in this dissertation presents a methodology to experimentally predict and simulate the mechanical behavior of polymers under high strain rate deformation. Specifically, the interplay between the effects of temperature and strain rate on polymer behavior is examined and then used as a tool to help recreate the high rate mechanical response of several different polymers: ranging from rubbers to amorphous polymers to composites. Multiple literature reviews are conducted and presented in this thesis, e.g. experimental mechanics test methods, high rate behavior, time-temperature equivalence, constitutive modeling, and temperature measurement methods. In accordance with mechanical theory, an experimental and analytical protocol in rate- and temperature- dependence was applied to a range of PVC materials ranging in plasticizer contents. Further to this, these PVC materials were modeled with a rubbery model describing the network stress seen in polymer behavior, and an amorphous polymer model to describe PVC low to high rate responses to deformation. This modeling develops insights in the adiabatic nature of high rate response. Time-temperature equivalence, and the temperature rise during adiabatic deformation, are studied and exploited in order to implement a proposed experimental method which simulates the high rate deformation of polymeric materials. The development of an experimental methodology to simulate and predict high rate behavior is presented, applied, and expanded to a range of materials: amorphous polymers (e.g. PVC 20wt% plasticizer, PMMA, PC) and composites (e.g. polymer bonded explosive simulant). The work also presents and highlights the fact that micro to nano-scale imaging may be used in parallel with the simulation method in order to better understand high rate behavior. Furthermore, in result of the studies conducted in this body of work, several novel techniques were developed, or improved upon, and applied to the current research (e.g. additions to time-temperature equivalence, temperature measurement methods at high, moderate, and low strain rates, and a method for measuring the high rate behavior of soft materials).

Les durées de vie classiques des pièces en aéronautique sont de plusieurs dizaines d’années. Cependant, certaines applications en marge impliquent des durées de vie bien plus courtes, sans réparation ou récupération des pièces. Les modèles de conception classiques doivent être adaptés et la démarche du choix matériau se faire « au juste besoin », autorisant l’utilisation des matériaux aux conditions limites de leur intégrité. Afin d’estimer ces limites, la caractérisation à plus hautes températures d’alliages existants est entreprise. C’est dans cette optique que se placent les travaux de thèse présentés dans ce manuscrit. L’alliage étudié est le Ti-6Al-4V (TA6V) forgé qui possède à l’issu du traitement thermomécanique une microstructure duplex. Il est actuellement l’alliage de titane le plus couramment utilisé en aéronautique et son utilisation est généralement limitée aux environs de 350°C pour des durées de vie classiques. Dans le but d’utiliser cet alliage pendant une dizaine d’heure, l’étude menée consiste à caractériser le TA6V de 20°C à 600°C. La caractérisation se centre, dans un premier temps, sur l’état métallurgique de la matière initiale issue du galet forgé et sur sa stabilité en température. Ensuite, le comportement mécanique du TA6V est étudié de 20°C à 600°C en traction, mettant en évidence une sensibilité de la contrainte d’écoulement à la vitesse de déformation dépendant de la température. Ce comportement est mis en lien avec le phénomène de vieillissement dynamique. La caractérisation du comportement mécanique est poursuivie par une campagne étendue de fluage de 20°C à 600°C pour différents niveaux de contraintes (de 0,3 à 1 fois la limite d’élasticité en traction). Ces essais montrent différents comportements en fonction de la température. La matière déformée en traction et en fluage est analysée en microscopie électronique en transmission afin d’apporter des informations sur les mécanismes de déformation gouvernant les différents comportements de l’alliage. Les campagnes de caractérisation en traction et en fluage ont permis d’établir un modèle de comportement viscoplastique du TA6V de 20°C à 600°C validé par l’ajustement des résultats obtenus à l’issue d’essais thermomécaniques complexes avec la simulation de ces essais par éléments finis. La corrélation des résultats en traction et en fluage et la détermination des mécanismes de déformation conduit à une discussion sur le comportement viscoplastique du TA6V, pour finalement aboutir à une proposition de modélisation du fluage du TA6V de 20°C à 600°C. Le modèle permet de reproduire qualitativement des courbes de fluage à partir de la sensibilité à la vitesse de déformation mesurée au cours d’essais de traction. / Classical life time of aeronautic parts lasts several decades. However, for some special applications with short life time and without repairs or recovery of parts, material design is tailored “close to real needs”. This justifies characterization at higher temperatures of well-known alloys and not developing new alloys. The study presented in this manuscript is included within this frame of short life applications. Forged Ti-6Al-4V (Ti-64) alloy with a bimodal microstructure is the most common titanium alloy in aeronautic and is usually limited below 350°C applications during classical life time. In order to use this alloy during a ten hour application, this thesis consists in characterizing Ti-64 from 20°C to 600°C. In a first time, characterization is focused on initial metallurgical state coming from a forged billet and on its thermal stability. Then, mechanical behavior of Ti-64 is studied by tensile testing from 20°C to 600°C, highlighting strain rate sensitivity (SRS) of flow stress. SRS is depending on temperature. This dependency is usually due to dynamic strain ageing phenomenon. Mechanical behavior characterization continues with creep testing from 20°C to 600°C for several stress levels (from 0.3 to 1 time yield stress values). Different behaviors versus temperature are revealed. Deformed samples by tensile testing and creep testing are analyzed by transmission electronic microscopy to bring information about deformation mechanisms controlling the different behaviors of the alloy. Thanks to tensile and creep testing, a viscoplastic modeling of Ti-64 from 20°C to 600°C has been performed and validated by fitting results from complex thermo mechanical tests with finite elements simulations. Comparison of mechanical behavior with deformation mechanisms leads to a discussion about viscoplasticity of Ti-64, and finally results in a proposal modeling creep behavior of Ti-64 from 20°C to 600°C. The model is able to estimate qualitatively creep curves using strain rate sensitivity measured during tensile tests.

Dans ce travail, des modèles thermomécaniques basés sur une approche non-locale sont proposés pour décrire le comportement des Alliages à Mémoire de Forme (AMF) avec la prise en compte des effets de la localisation et de la chaleur latente lors de la transformation de phase. Ces modèles sont obtenus comme des extensions d’un modèle local existant. Pour décrire la localisation de la transformation de phase, l’extension du modèle initial a consisté à le réécrire dans un contexte non-local par l’introduction d’une nouvelle variable, définie comme la contrepartie non-locale de la fraction volumique de martensite déjà présente dans le modèle local. L’exploitation de ce modèle a nécessité le développement d’un élément fini spécial dans ABAQUS avec la fraction volumique non-locale de martensite comme un degré de liberté supplémentaire. Les simulations réalisées montrent la pertinence d’une telle approche dans la description de la transformation de phase dans des structures minces en AMF, soumises à des chargements thermomécaniques. Pour décrire les effets de la chaleur latente, une équation d’équilibre thermique ayant comme terme source des contributions dépendant de la transformation de phase a été adjointe au modèle initial. Là encore, l’exploitation du modèle a nécessité le développement d’un élément fini qui prend en compte le couplage thermomécanique et la formulation proposée pour l’équilibre thermique. Les simulations numériques réalisées ont montré l’effet retardant sur la transformation de phase de la chaleur latente, et le caractère hétérogène possible de la transformation dans ce cas. Ces effets sont d’autant plus importants que la vitesse de déformation est élevée / In this Phd thesis, thermo-mechanical models based on a nonlocal approach are proposed in order to describe the behavior of Shape Memory Alloys (SMA), taking into account localization and latent heat effects during phase transformation. These models are obtained as extensions of an existing local model. In order to describe the localization of phase transformation, the extension of the initial model consisted of rewriting it in a nonlocal context through the introduction of a new variable, defined as the nonlocal counterpart of the martensite volume fraction. The use of this model has required the development of a specific finite element in ABAQUS with the nonlocal martensite volume fraction as an additional degree of freedom. The simulations show the relevance of such an approach in the description of the phase transformation occurring in thin SMA structures subjected to thermo-mechanical loadings. To achieve the description of the latent heat effects, a heat balance equation with a source term depending on contributions of the phase transformation was added to the constitutive equations of the initial model. Even there, the use of the model required the development of a finite element which takes into account the thermo-mechanical coupling and considers the proposed formulation for the thermal balance. Numerical simulations have shown the delaying effect of the latent heat on phase transformation and the possible heterogeneous character of the phase transformation in this case. These effects are even more important as the strain rate is high

Les matériaux composites à matrice organique sont largement utilisés dans l'industrie des transports et notamment dans le domaine aéronautique. Pour permettre un dimensionnement optimal des structures, il est nécessaire d'étudier le comportement des matériaux CMO sur une large gamme de vitesses et de températures.L'objectif de cette thèse est de proposer un modèle de comportement et de rupture permettant de prédire la réponse des CMO sur une large gamme de vitesses de sollicitation et de températures. Les recherches se sont intéressées dans un premier temps à la caractérisation de la transition entre les régimes de comportement linéaire et non linéaire du matériau unidirectionnel T700GC/M21 (renforts de fibres de carbone, résine époxy), ainsi qu'à la dépendance de cette transition à la vitesse de sollicitation et à la température. Les travaux se sont ensuite focalisés sur l'étude expérimentale du régime de comportement non linéaire endommageable du T700GC/M21. Enfin, au terme de ces deux étapes, une version améliorée du modèle disponible à l'ONERA pour les composites stratifiés (OPFM) a été proposée, version intégrant un critère de transition linéaire/non linéaire de comportement, et une prise en compte de l'influence de la vitesse de sollicitation et de la température sur la réponse du matériau / Nowadays, organic matrix composite materials are widely used in the transportation industry, and particularly in the aeronautical industry. To provide an optimal dimensioning of the structures, it is necessary to study the mechanical behavior of OMC on a large range of strain rates and temperatures. The aim of this PhD thesis is to propose a behavior and a rupture model to predict the mechanical response of OMC for a large range of strain rates and temperatures. The research was initially focused on the characterization of the transition between the linear and nonlinear behavior of the material T700GC/M21, a carbon / epoxy unidirectional laminate as well as the strain rate and temperature dependencies of this transition. The work was then focused on the experimental study of the nonlinear damaged behavior of the T700GC/M21. Finally, completing these first two steps, an updated version of the behavior model available at ONERA (OPFM) was proposed which includes the transition between linear and nonlinear behavior and the influence of strain rate and temperature on the mechanical response of the material.