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Kyoto University (京都大学) / 0048 / 新制・課程博士 / 博士(エネルギー科学) / 甲第19091号 / エネ博第315号 / 新制||エネ||64 / 32042 / 京都大学大学院エネルギー科学研究科エネルギー基礎科学専攻 / (主査)教授 岸本 泰明, 教授 前川 孝, 教授 中村 祐司 / 学位規則第4条第1項該当

The occurrence of hot tearing during solidification is one of the major factors influencing both the quality and productivity of aluminum castings. In order to reduce the formation of hot tears, quantitative information regarding both hot tearing formation and semi-solid deformation is essential. In this study, the mechanisms of hot tearing and semi-solid deformation have been investigated via two novel techniques: x-ray micro-tomography on material deformed in the semi-solid region, and development of a three phase microstructural model based on a geometry derived from a Voronoi diagram with rounded corners and porosity. Numerical techniques were utilized to quantify both the size evolution and orientation of internal damage relative to void growth. In order to conduct the above research, a new semi-solid tensile deformation methodology was devised which uses a two thermocouple control technique to enable accurate measurement of semi-solid tensile strength and ductility. The experimental work was conducted on the aluminum – magnesium alloy AA5182 in the as-cast and hot isostatic pressing (HIP) states. The x-ray micro-tomography technique was used to observe that semi-solid deformation is accommodated by internal damage via growth of as-cast porosity and the nucleation of new damage-based voids. As the volume fraction of damage increases, the growth of voids occurs in an orientation perpendicular to the loading direction, both through expansion within the grain boundary liquid and via coalescence between voids. The damage then localizes, causing failure. The finite element semi-solid microstructural model was used to explore the effects of fraction solid, fraction porosity, and grain size on semi-solid constitutive behaviour. The simulations revealed that increased grain size and fraction porosity lead to a reduction in flow stress for a given fraction solid. Furthermore, local strain accumulation was linked to hot tearing, since strain localizes in the liquid very early in the deformation process. Based on the model predictions, a new constitutive relationship was developed over the range 0.75 < fs < 0.95. Together, these two techniques have provided powerful new insight, such as the critical role played by as-cast porosity, on the phenomena of hot tearing and semi-solid deformation in aluminum alloys.

Orientador: Prof. Dr. Francisco Eugenio Mendonça da Silveira / Dissertação (mestrado) - Universidade Federal do ABC, Programa de Pós-Graduação em Física, 2015. / Neste trabalho, apresentamos a instabilidade de tearing, um dos principais modos resistivos instáveis de um plasma e que possui relação direta com o fenômeno da reconexão magnética. Utilizando o modelo magnetohidrodinâmico, fazemos primeiro uma revisão da análise clássica encontrada na literatura e em seguida, propomos uma análise que leva em conta os efeitos inerciais dos portadores de carga, que se mostram relevantes em altas frequências. Mostramos que, ao contrário da abordagem clássica, nossa análise conduz à um limite superior finito para a taxa de crescimento da instabilidade. / In this work, we study the tearing instability, one of the principal unstable resistive modes in a plasma and that is closely related to the magnetic reconnection phenomenon. By making use of the magnetohydrodynamic model, initially we revise the classical analysis, as it is done in the literature and following that, we propose an analysis which takes into account inertial effects due to charged species, that show to be relevant in high frequencies. We show that, unlike the classical approach, our analysis leads to a finite upper-bound for the growth rate of the instability.

La fissuration à chaud est un défaut majeur intervenant en fin de solidification d'alliages métalliques, lorsque le matériau est encore à l'état semi solide. L'objectif de cette thèse est d'apporter une contribution à la prévision de ce phénomène. Pour cela il est nécessaire de caractériser la déformabilité de la phase solide d'un matériau à l'état semi solide et d'apporter des informations au niveau local sur la microstructure lors de sa déformation (fractions de liquide et de pores, épaisseur de films de liquide, vitesses d'écoulement du liquide, indice de coalescence des pores...). Le comportement macroscopique de la phase solide sur la ligne de solidus a été déterminé et validé par des essais de compression à chaud. Cette loi de comportement a également été comparée avec plusieurs modèles analytiques. La différence de comportement mécanique entre une microstructure de composition homogène et une microstructure à gradient de composition a été mise en évidence. Des informations microscopiques en temps réel sur des échantillons à l'état semi solide soumis à un effort de traction ont été obtenues par microtomographie in situ standard en conditions isothermes et en solidification. Un modèle analytique prédictif de la fissuration à chaud a été modifié pour mieux rendre compte des valeurs expérimentales. Pour gagner en résolutions temporelle et spatiale, un dispositif de traction destiné à l'utilisation de la microtomographie in situ rapide ou ultra rapide a été conçu et réalisé. Les essais en conditions isothermes et en solidification sont désormais reproductibles sur une microstructure obtenue par refusion. Des phénomènes rapides au sein d'une microstructure très fine sont maintenant observables. / Hot tearing is a defect which forms at high solid fraction in solidifying alloys, when the material is still semi solid. This work aims at bringing a contribution to the prevision of this phenomenon. To be able to do that, it is necessary to characterize deformability of the semi-solid alloy solid phase, and also bring local information on microstructure during its straining (liquid and pore fractions, liquid films thickness, liquid flow velocity…). Solid phase macroscopic behaviour on solidus line has been determined and validated by hot compression tests. The calculated behaviour law has also been compared with several analytical models. Mechanical behaviour differences between homogeneous and composition gradient microstructure has been put in evidence. Real time microscopic information on tensile tested semi solid samples have been obtained by in situ standard microtomography, in isothermal and solidification conditions. An analytic hot tearing predictive model has been modified to better fit the experimental data. An experimental device has been developed and realized to be able to carry out high and ultra high speed microtomography. These two methods bring better both time and space resolution. High velocity phenomenons in very fine microstructures can thus be visible. Isothermal and solidification conditions tests and now reproducible on remelted samples.

La construction d’un ouvrage hydraulique commence par le choix des matériaux devant le constituer. Les sols employés pour la construction d’ouvrages hydrauliques en terre peuvent être constitués de matériaux perméables tels que les sables ou les graves ou de matériaux peu perméables tels que les argiles ou les limons. En fonction de la disponibilité des matériaux à proximité du chantier, il est alors possible d’opter pour différents types d’ouvrages (ouvrages homogènes, à noyau ou zonés). Dans tous les cas, le coût d’un ouvrage tel qu’une digue est d’autant moins élevé que les sols utilisés pour sa construction sont issus de zones proches du chantier. Lorsque des sols sont disponibles en quantité suffisante à proximité du chantier mais que leur utilisation soit risquée pour la stabilité de l’ouvrage, il peut être opportun de chercher à modifier leurs caractéristiques pour qu’ils puissent être utilisés dans les mêmes conditions de sécurité que les matériaux traditionnels. C’est autour de cette problématique que ce travail de thèse a vu le jour. En particulier, ce travail vise à étudier les améliorations apportées par un traitement à la chaux appliqué sur un sol grossier soumis à un écoulement interne afin de le stabiliser contre le phénomène de l’érosion interne. La compréhension des améliorations apportées a nécessité la mise en place d’une analyse multicritère au travers d’essais dédiées. Dans la première partie de la thèse, nous nous sommes employés à développer un dispositif d’essais permettant de réaliser des essais d’érosion interne sur ce type de sol. Ce dispositif nous a permis de réaliser une étude phénoménologique sur le comportement du sol considéré, soumis à des écoulements, en fonction du sens de l’écoulement et de l’application ou pas du traitement. Par la suite une étude paramétrique a été réalisée afin de mettre en évidence l’influence des paramètres principaux : dosage de traitement, temps de cure, hauteur de l’éprouvette et surcharge. Dans une seconde partie, nous nous sommes intéressés à l’influence de l’immersion des échantillons dans l’eau sur leur stabilité. A cet effet, l’essai de dispersion, adapté à ce type de sol, a pu être utilisé et exploité. Des essais complémentaires de résistance à la compression simple ont été réalisés afin d’estimer la perte de résistance après immersion. Ce qui nous a poussés à examiner l’existence de corrélations entre les propriétés à l’érosion et les propriétés mécaniques du sol traité / The construction of a hydraulic structure starts with the selection of the materials that will constitute it. The soils used in the construction of hydraulic earthen structures may be made of permeable materials such as sands or low permeability materials such as clay or silt. Depending on the availability of materials near the site, it is possible to choose different types of structures (homogeneous structures, core or zoned). In all cases, the cost of such a structure as a dike is even lower than the soils used for its construction come from areas near the site. When soils are sufficiently available near the construction site, but their use is risky for the stability of the structure, it may be appropriate to seek to modify their characteristics so they can be used in the same security conditions than traditional materials. It is around this issue that this thesis was born. More particularly, this research aims to study the improvements made by a lime treatment on a coarse soil subjected to internal flow to stabilize against the phenomenon of internal erosion. Understanding improvements requires the establishment of a multi-criteria analysis through dedicated tests. In the first part, we are interested in developing a testing device for performing internal erosion tests on this type of soil. This device has enabled us to realize a phenomenological study of the phenomena observed with the direction of flow and the presence or not of the treatment. Subsequently a parametric study was conducted to highlight the influence of the main parameters: treatment dosage, treatment time, height of the specimen and overload. In the second part, we studied the influence of immersion samples in water for this purpose the crumb test test was adapted for this type of soil. Additional unconfined compression tests were conducted to estimate the loss of strength after immersion. This allowed us to try couplings between the properties to erosion and soil treated mechanical properties

The occurrence of hot tearing during solidification is one of the major factors influencing both the quality and productivity of aluminum castings. In order to reduce the formation of hot tears, quantitative information regarding both hot tearing formation and semi-solid deformation is essential. In this study, the mechanisms of hot tearing and semi-solid deformation have been investigated via two novel techniques: x-ray micro-tomography on material deformed in the semi-solid region, and development of a three phase microstructural model based on a geometry derived from a Voronoi diagram with rounded corners and porosity. Numerical techniques were utilized to quantify both the size evolution and orientation of internal damage relative to void growth. In order to conduct the above research, a new semi-solid tensile deformation methodology was devised which uses a two thermocouple control technique to enable accurate measurement of semi-solid tensile strength and ductility. The experimental work was conducted on the aluminum – magnesium alloy AA5182 in the as-cast and hot isostatic pressing (HIP) states. The x-ray micro-tomography technique was used to observe that semi-solid deformation is accommodated by internal damage via growth of as-cast porosity and the nucleation of new damage-based voids. As the volume fraction of damage increases, the growth of voids occurs in an orientation perpendicular to the loading direction, both through expansion within the grain boundary liquid and via coalescence between voids. The damage then localizes, causing failure. The finite element semi-solid microstructural model was used to explore the effects of fraction solid, fraction porosity, and grain size on semi-solid constitutive behaviour. The simulations revealed that increased grain size and fraction porosity lead to a reduction in flow stress for a given fraction solid. Furthermore, local strain accumulation was linked to hot tearing, since strain localizes in the liquid very early in the deformation process. Based on the model predictions, a new constitutive relationship was developed over the range 0.75 < fs < 0.95. Together, these two techniques have provided powerful new insight, such as the critical role played by as-cast porosity, on the phenomena of hot tearing and semi-solid deformation in aluminum alloys. / Applied Science, Faculty of / Materials Engineering, Department of / Graduate

Nuclear Reactor Pressure Vessels (RPV) are manufactured from medium strength low alloy ferritic steel, specifically selected for its high toughness and good weldability. The ability of the RPV material to resist crack growth is crucial given that it is one of the fundamental containment safety systems of nuclear power plants. For most of their lifetime, the RPV operates at sufficiently elevated temperatures to ensure the material is ductile. However, the development of ductile damage, in the form of voids, and the ability to predict ductile tearing in RPV materials using a mechanistically-based model remains difficult. The Gurson-Tvergaard-Needleman (GTN) model of ductile tearing provides one such tool for predicting ductile damage development in RPV materials. The difficulty in using the GTN model lies in the ability to calibrate the model parameters in a robust manner. The parameters are typically calibrated data, derived from fracture tests and relying on an iterative “trial and error” procedure of numerical simulations and comparison with test data until the model reproduces the experimental behaviour with sufficient accuracy. This research has addressed the development of a mechanistically-based approach to the calibration of the GTN model by developing a new understanding of the ductile fracture mechanism in RPV material through conventional metallography and 3D X-ray computed tomography to image the initiation, growth and coalescence of ductile voids. The metallographic and tomographic data were analysed in a quantitative manner to establish a direct link between the microstructural features and void evolution and the key parameters of the GTN model. This approach has established a more robust mechanistically based method for the calibration of the GTN model that will enhance the conventional iterative calibration procedure. The calibrated model was applied to predict ductile tearing behaviour in compact-tension and notched-tensile specimens. The results showed good agreement with test data and also reproduced the morphology and branching of crack extension observed in practise. Whilst these observations were due, in part, to the numerical solving procedure, they enabled new insights to be gained regarding the development of non-uniform void volume fraction distributions in tested specimensThe results from this research will strengthen the guidance provided to structural integrity engineers in industry regarding the calibration and application of ductile damage mechanics models such as the GTN model for predicting ductile initiation and growth in RPV materials.

Content: Leather is a kind of natural biomass composite material which is made of animal skin as material by a series of chemical and physical processing. Its main structure is Collagen fibers of three-dimensional network structure. As we all know sheep leather always exist a common problem with low strength, while the strength of leather depended on the woven degree of collagen fibers. Through the past decades, many methods have been tried to improve the properties of sheep leather. The most commonly used methods are retanning. However, the strength enhancement of sheep leather is extremely limited by retanning, although the fullness and softness may be improved. In this study, a new type of multi-epoxy reinforcement agent (IGE) and IGE with the synergistic effect of polyamine (IGE-PA) were used to enhance the strength of sheep leather in tanning and fatliquoring process. Comparing with chromium tanned leather, it was found that under the optimized conditions (dosage: 10%, pH: 8, Temperature: 35℃ for penetration and 45℃ for fixation, tanning time: 10 h) with IGE as the main tanning agent, the tearing strength was increased 56.8%. While when the polyamine as the synergetic agent for IGE, the tearing strength was significantly increased 87.9%. While IGE and IGE-PA were used in fatliquoring process, it has significant reinforcement effect for tetrakis hydroxymethyl phosphonium (THP) salt tanned leather. It was found that under the optimized conditions (Dosage: 2.5%, pH: 7-8, Temperature: 50℃, Time: 2h) with IGE in fatliquoring process, the tear strength was increased 50.24%, while the IGE-PA was used, the tear strength was increased 64.3%. Furthermore, TGA results showed that decomposition temperatures of IGE and IGE-PA enhanced leather were all higher than traditional chromium tanned leather. In addition, SEM results showed that IGE and IGE-PA enhanced leather obtained better opened-up fiber structure. Take-Away: 1. A new type of multi-epoxy tanning agent (IGE) has reinforcement effect for sheep leather especially in tear strength. 2. IGE with the synergistic effect of polyamine (IGE-PA) were used in tanning process, which has a significant enhancement for the sheep leather. 3. IGE and IGE-PA can be also used in fatliquoring process to enhance the strength of sheep leather.

Thin polymer materials are today widely used in industry and production. An ordinary food package can have around six different layers of materials laminated together to obtain the desired protection. To obtain an efficient usage of these materials simulations are often required. But the simulations require precise and good material models and properties. To obtain these properties through standard tests are difficult as normal strain gauges or extensometers can’t be used. Much research has been done on this kind of material. But still, the knowledge of the behaviour in certain cases is limited. One such area is the tearing of a laminated material.   The first objective of the work is to test a new measurement method, Digital Image Correlation (DIC), for thin polymer films and test if the method is applicable. DIC is a non-contact measurement technique that measure the deformation of a stochastic pattern. The strain is then calculated from this deformation. These strains can then be used to obtain material properties and behaviour. The second objective is to test the tearing behaviour of a laminate.   The material used is a laminate between a PET (100 μm) and LDPE (25 μm) film. When testing the single layers they were carefully delaminated with a plexiglass staff. As the material can be anisotropic the materials were tested in five directions: Machine Direction (MD); 22,5˚; 45˚; 67,5˚ and Cross Direction (CD). The work and tests were performed at BTH Campus Gräsvik.   An experimental setup for DIC with the usage of chalk spray and backlight was tested. Five tests were performed with and without DIC pattern. It was calculated that the DIC specimens were within standard deviation of the reference tests. GOM Correlate was used to evaluate the strains and visualise the distribution. The strains obtained were also used to calculate the true stress of the specimens and estimate the Poisson’s ratio.      Through testing it was concluded that the tearing of the laminate led to delamination in one of the legs. The delamination always appears in the leg where the LDPE film will experience tensile forces. The crack also angels towards 45˚. By testing single layers it was found that the PET film angles when teared, likely caused by the anisotropy of the material.      An experimental setup for the use of DIC for thin polymer has been developed. This method can be used for future measurements and improvement of material models. The behaviour of laminated tearing was observed and some conclusions could be drawn about its behaviour. However, a lot more work is required on this subject.