This thesis investigates the cooling behaviour of polymers during the microinjection moulding process. The work included bespoke experimental mould design and manufacturing, material characterisation, infra-red temperature measurements, cooling analysis and cooling prediction using commercial simulation software. To measure surface temperature of the polymers, compounding of polypropylene and polystyrene with carbon black masterbatch was performed to make materials opaque for the IR camera. The effects of addition of carbon black masterbatch were analysed using differential scanning calorimetry and Fourier transform infrared spectroscopy. Sapphire windows formed part of the mould wall and allowed thermal measurements using an IR camera. They were laser machined on their inside surfaces to generate a range of finishes and structures. Their topographies were analysed using laser confocal microscope. The surface energy of sapphire windows was measured and compared to typical mould steel, employing a contact angle measurement technique and calculated using Owens-Wendt theory. A heating chamber was designed and manufactured to study spreading of polymer melts on sapphire and steel substrates. A design of experiments approach was taken to investigate the influence of surface finish and the main processing parameters on polymer cooling during microinjection moulding. Cooling curves were obtained over an area of 1.92 by 1.92 mm of the sapphire window. These experiments were conducted on the Battenfeld Microsystem 50 microinjection moulding machine. A simulation study of polymer cooling during the microinjection moulding process was performed using Moldflow software. Particular interest was paid to the effect of the values of the interfacial heat transfer coefficient (HTC) on the simulated cooling predictions. Predicted temperature curves were compared to experimentally obtained temperature distributions, to obtain HTC values valid for the material and processing parameters.

Contact resistance is the most important and universal characteristic of all types of electrical and thermal contacts. Accurate measurement of contact resistance is important, because it serves as a measure for judging the performance and operational life span of contacts. Rise in contact temperature is one of the major factors that pose a big threat to the stability of electrical contacts. Dissipation of heat by solid conduction through a contact interface is governed by its thermal contact conductance (TCC). This emphasizes the need to study the TCC of an electrical contact along with its electrical contact resistance (ECR). Simultaneous measurement of ECR and TCC is important for understanding the interconnection between these two quantities and the possible influence of one over another. Real time experimental data and analytical correlations can be extremely helpful in developing electrical contacts with improved thermal management capabilities. As a part of the experimental investigation, a test facility has been developed for making simultaneous measurement of ECR and TCC across flat contacts. The facility has the capability of measuring ECR and TCC over a wide range of operating parameters, such as contact pressure, contact temperature, interstitial gaseous media, ambient pressure, etc. It is also capable of determining the electrical resistivity and thermal conductivity of materials as a function of temperature, which is very helpful in analyzing the generated contact resistance data. Using this facility, simultaneous ECR and TCC measurements are made across bare and gold plated contacts of OFHC Cu (oxygen free high conductivity copper) and brass. Simultaneous ECR and TCC measurements are made on nominally flat contacts in the contact pressure range of 0 – 1 MPa and the interface temperature range of 20 – 120 °C. Effect of contact pressure and interface temperature on ECR and TCC is studied on bare and gold coated contacts in vacuum, N2, Ar, and SF6 environments. TCC strongly depends on the thermophysical properties of the interstitial media and shows a significant enhancement in gaseous media, because of the increased interfacial gap conductance compared to vacuum. The gas pressure is varied in the range of 1 – 2.6 bar to study its effect on the gap conductance at different contact pressures and interface temperatures. Minor increase in the ECR observed in gaseous media is found to be independent of the properties of the media. Experimental results indicated that ECR depends on the gas pressure as well as on the applied contact load. Effect of gold coating and its thickness on the ECR and TCC across OFHC Cu and brass contacts is studied. Measurements on electroplated gold specimens having different gold layer thicknesses (0.1, 0.3, and 0.5 µm) indicated that ECR decreases and TCC increases with increasing gold coating thickness. Effect of gold coating on the substrate properties, contact surface tomography, and microhardness is analyzed and correlated to the observed behavior of ECR and thermal gap conductance. An attempt is made to understand and quantify the changes in the contact surface characteristics due to contact loading and heating, by measuring various surface topography parameters before and after the experimentation. Effect of thermal stresses (generated due to temperature variations) on ECR and TCC is studied and inclusion of an experimentally measured temperature dependent load correction factor is suggested in the theoretical models to take into account the effect of thermal stresses in contact assemblies.

Οι κατασκευές των περισσοτέρων τεχνολογικών εφαρμογών υπόκεινται σε σύνθετες θερμικές καταπονήσεις. Παράλληλα, η επεξεργασία σύγχρονων υλικών συνήθως συνδέεται με ειδικές θερμικές κατεργασίες. Η πολυπλοκότητα στη γεωμετρία των κατασκευών αυτών σε συνδυασμό με τις απότομες μεταβολές της θερμοκρασίας και γενικότερα της επιβαλλόμενης θερμικής καταπόνησης, συχνά οδηγεί στη λύση της συνέχειας των υλικών μέσω της δημιουργίας ρωγμών η οποία μειώνει τα επίπεδα αξιοπιστίας και παράλληλα αυξάνει δραματικά το κόστος συντήρησης και παραγωγής τους. Οι θερμικές φορτίσεις των ρηγματωμένων κατασκευών οι οποίες συνδέονται σχεδόν πάντα με απορρόφηση θερμότητας και επομένως ταυτόχρονη διαστολή των υλικών, οδηγούν στο λεγόμενο «κλείσιμο» της ρωγμής κατά το οποίο οι επιφάνειες της ρωγμής έρχονται τμηματικά ή και εξολοκλήρου σε επαφή δηλαδή συμβάλλουν. Εξαιτίας της πολυπλοκότητας και της μη γραμμικής φύσης του προβλήματος της επαφής, o χαρακτηρισμός της θερμικής θραύσης, υπό την παρουσία φαινομένων συμβολής των επιφανειών της, δεν έχει διερευνηθεί διεξοδικά στη βιβλιογραφία. Η επικρατούσα παραδοχή, ότι δηλαδή η ρωγμή παραμένει εντελώς ανοιχτή κατά τη θερμική φόρτιση, οδηγεί σε εσφαλμένα αποτελέσματα και επομένως δεν έχει πρακτική αξία στον κατασκευαστικό σχεδιασμό. Για το λόγο αυτό, η ανάπτυξη ενός αξιόπιστου και οικονομικού από απόψεως υπολογιστικής ισχύος αριθμητικού εργαλείου για την αντιμετώπιση τέτοιων προβλημάτων είναι αναγκαία. Η αριθμητική προσομοίωση και ο χαρακτηρισμός, μέσω της μεθόδου των συνοριακών στοιχείων, της θερμικής θραύσης η οποία επηρεάζεται από το φαινόμενο της επαφής των επιφανειών της ρωγμής είναι ο σκοπός της παρούσας διατριβής. / The structures of most technological applications are subject to complicate thermal loadings. Additionally, the processing of modern materials is usually related with special thermal treatments. The complex geometry of these structures in combination with the rabid changes of the temperature and generally with the imposed thermal load, often leads to the dissolution of continuity of the materials via the creation of cracks, fact that decreases the reliability standards and simultaneously increases dramatically the maintenance and manufacturing cost. The thermal loadings of the cracked structures which are associated with heat absorption and consequently simultaneous dilation of materials, lead to the well known crack closure phenomenon in which the surfaces of the crack come partially or even entirely into contact i.e. they interfering. Due to the complexity and non linear nature of the contact problem, the fracture characterization under crack closure phenomena has not been investigated thoroughly in the literature. The prevalent assumption, that the crack remains completely open during thermal loading, leads to inaccurate results and thus is not of practical importance in structural design. Therefore, the development of a reliable numerical tool offering low computational cost is required for the treatment of such problems. The numerical simulation and characterization, through the boundary element method, of thermal fracture that is influenced by crack closure phenomenon is the aim of the present thesis.

Metal foams have many attractive properties such as light weight, low relative density, energy absorption capability etc. One of the main advantages of metal foam is that the foam inherits several properties of the parent metal, at the same time, at a fraction of the weight. Metal foams are basically of two types; closed pore and open pore. In the open pore configuration the highly porous structure with large surface to volume ratio is attractive in thermal applications such as heat exchangers, small scale refrigeration, diesel exhaust cooling and heat sink for electronics. Large surface area to volume ratio of the heat transfer area is an important parameter in design of heat exchangers. Application of open cell metal foam as a heat exchanger involves production of the metal foam, cutting/drilling the metal foam to required dimensions and attaching it to a substrate or duct. Foams are cut by various methods such as by using circular saw, band saw, abrasive sawing wire or electrical discharge machining. Cutting or drilling operations plastically deform the struts and affect the surface roughness of the struts and hence, the contact area between the foam and the substrate. The foam and the substrate are then joined to get the final product. Various techniques are adopted to join the foam and substrate that includes, press fit, welding, soldering, brazing and use of epoxy adhesives or thermal glue. These methods either deform the foam plastically or involve a bonding material which involves an additional step in manufacturing and is generally necessary to reduce the thermal resistance at the interface. Every secondary step involved in machining the foam and joining it to substrate/duct add to the energy, time and cost of the component. Significant amount of materials wastage occurs during the production and machining steps of the metal foam. Bonding material used for attaching foam to the substrate makes the recycling of the heat exchangers difficult. In the present research work the above issues were rectified by introducing a novel method of fabricating the heat exchanger in a single step. This can be done by producing open cell foam, bonded to the substrate in a single step to get the ready to use heat exchanger. The uniqueness of the method/ process is that it provides an advantage of manufacturing heat exchangers consisting of open cell aluminium foam both inside and outside the aluminium duct/substrate. Here open cell metal foam is metallurgic ally bonded to the aluminium duct without producing any distortion in the aluminium duct. The present method avoids the secondary cutting and joining operations, hence reducing material and energy wastage. This heat exchanger does not need a bonding material at the foam duct interface which makes the product completely recyclable without even having to separate the aluminium foam and, many-at-times, the copper substrate. Further, in the present process no hazardous material is involved in the fabrication process of the heat exchanger and all the materials used for the foam production can be recycled. Another unique advantage of this process is that the foam can also be cast inside and outside the tube in a single step. This helps increase the heat transfer area per unit volume inside the tube increasing the effectiveness significantly. First, an attempt was made to cast aluminium foam over a Cu substrate. Spheres made of Plaster of Paris (PoP) were used as space holders to create pores in the foam. First, a dough of PoP was prepared by mixing sufficient amount of water with the powder of PoP. Small pieces of PoP were taken from the dough and were rolled by hands to prepare spherical balls. Next, a casting setup was made where a die made of stainless steel was placed in a crucible whose bottom was filled with sand. A tube/duct made of copper was placed at the centre of the die and PoP balls were dropped around the duct. This setup was then placed in a furnace and was preheated to remove all the moisture from the PoP. Molten aluminium at around 700 °C was poured into the preheated die. After solidification, the die was opened and cast was allowed to cool in ambient air. PoP balls were removed by using a sharp needle and by dipping the casting in acetic acid. After removal of PoP from the cast, interconnected holes/cavities formed in the place of space holders/PoP balls, forming pores in the foam. There are some limitations of this method such as removal of PoP was tedious and needed chemicals that need to be discarded, PoP cannot be recycled and creates waste, small amount of moisture present in PoP balls can cause an explosion. The bonding between aluminium foam and Cu substrate obtained was not good, giving rise to thermal contact resistance. Due to the above limitations further implementation of this process using PoP was not explored further. There was a need of space holder material which can withstand the temperature of molten Al and also can be removed easily from the cast without any use of chemicals. Obtaining metallic bonding between foam and Cu substrate was difficult due to the corrosion layer formation at the interface of Al and Cu substrate due to preheating. If preheating was not carried out full penetration of the molten aluminium did not take place in the space available in between the spheres. Therefore, it was decided to cast Al foam over Al substrate. The main challenge and difficulty was to cast open cell Al foam inside and outside the tube/duct made of the same material (Al) without distorting the tube/duct as well as achieving consistent metallic bonding between the two. This has been successfully done by gravity casting method a single step manufactured and ready to use open cell Al foam heat exchanger were fabricated. A casting setup was prepared, which consisted of a commercially pure aluminium tube placed in the middle of a stainless steel split die. The gap between the tube and die was filled with the salt spheres. An uncommon and new approach was adopted to produce NaCl salt spheres. NaCl salt balls (spherical and ovoid) of different diameters were processed by casting route. The casting step of NaCl is necessary as the moisture present in NaCl can be completely removed during the melting of NaCl. NaCl was chosen as it had a melting point higher than aluminium. The casting setup was placed in a furnace and was preheated to various temperatures up to 550 °C. Commercially pure aluminium was melted separately in a crucible and was poured into the steel die at 700oC. The liquid metal flows through the die and fills the cavities between the salt balls. The die was opened immediately after solidification of molten Al and cast was allowed to cool in ambient air. The salt (NaCl), which was still solid, was dissolved in water to get the foam structure. With proper control of the preheat temperature and temperature of liquid aluminium no distortion of the aluminium duct was observed throughout the length of the heat exchanger. Consistent and complete fusion/ metallic bonding was observed at the interface of Al foam and Al substrate/duct. Several heat exchangers with different porosity and pore geometry with the aluminium foam cast outside the tube and both inside and outside of the tube were fabricated. The beauty of the designed method is that it is simple and cost effective and eliminates the major issue of thermal contact resistance since the foam and the duct are made of the same material and are bonded in the liquid state leaving no interface between the foam and the duct. Further, foam can also be cast inside the duct in the same step while casting the foam outside the tube, giving an integral heat exchanger which has higher heat transfer surface area to volume ratio inside and outside the duct. This is expected to further improve the efficiency and effectiveness of the heat exchanger An added advantage of this method is that the heat exchanger can be recycled easily in a single step re-melting route. Further, the heat exchanger does not use any hazardous material during manufacture that needs attention during recycling. After the production and fabrication of the heat exchangers, the thermal performance or effectiveness of the heat exchangers was assessed, to evaluate its usefulness and suitability for heat transfer application. An experimental test setup was fabricated in the laboratory to perform the heat transfer tests. The experimental test setup consists of the following major components;1) A test chamber whose function was to insulate the heat exchangers from the surroundings and to avoid any heat loss to the surroundings, 2) An air blower used to supply cold fluid (air) to the test chamber, 3) A constant temperature bath was used to supply the hot fluid, which was water in this case, in the duct of the heat exchanger, 4) A rotameter was used to measure the volumetric flow rate of the cold fluid and 5) A pressure gauge having the pressure measurement range between 1 mbar to 160 mbar to measure the pressure drop across the test chamber. K-type chromel – alumel thermocouples having temperature measurement range between -270 °C to 1,260 °C were used to measure the temperature of hot and cold fluids during the experiments. By aid of the data logger system and computer, temperature readings were recorded during the tests and were used further for the heat transfer calculations. For testing the aluminium foam heat exchangers was placed in the insulated test chamber. Hot water was supplied inside the duct of heat exchanger whereas air at room temperature was supplied around the foams at varying flow rates during the tests. During the tests, temperature readings were taken at steady state condition. NTU-Effectiveness method was used to evaluate the thermal performance of heat exchangers. Overall results obtained by this experimental study are as follows • As the inlet temperature difference between hot and the cold fluids increases the heat transfer rate and the effectiveness of the heat exchangers also increases. • At a constant flow rate of hot fluid, heat exchangers exhibits significantly better thermal performance at lower flow rate of cold fluid compared to higher flow rate. As the flow rate of cold fluid increases, the velocity of the fluid increases and consequently, reduces the optimum interaction time between hot and the cold fluids required for the efficient heat transfer. • At a constant and low flow rate of cold fluid the effectiveness of the heat exchanger increases as the porosity of the foam increases. But when the flow rate of cold fluid was increased further after a certain limit, the effectiveness value of the heat exchanger decreases. • Heat exchanger consisting of foam of higher porosity exhibits higher effective. • Heat exchanger having foam inside and outside of the duct/tube exhibits significantly higher effectiveness compared to Al duct, Cu duct and other heat exchanger tested. • At a higher flow rate of the cold fluid, the heat exchangers consisting of foams of higher porosity, experience more drop in effectiveness compared to the heat exchanger having foams of low porosity. • Pressure drop across the length of the foam/fin increases as the volumetric flow rate of the cold fluid (m3/s) increases. • Surface area per unit volume and effectiveness values for bare Al tube is very low compared to Al foam heat exchangers resulting in the bare Al tube exhibiting much lower effectiveness compared to heat exchanger made of Al foam. • For a certain flow rate of fluids, the effectiveness of the heat exchanger increases up to a certain thickness of the Al foam. • Regardless of the thickness of the foam, the effectiveness of the heat exchangers is low at higher flow rate of cold fluid compared to lower flow rate. • These foam based heat exchanger had a much higher effectiveness when compared to that of other heat exchangers, data of which were got from literature. The present experimental study concludes that fuse bonding open cell aluminium foam over an Al duct or Al substrate can improve the thermal performance of the heat exchanger significantly. The thesis includes five chapters. Chapter 1 gives a detailed introduction about the metal foam, heat exchangers, thermal contact resistance and its effect on the heat transfer rate has been explained. This chapter also includes the overall aim and motivation for the research work. Chapter 2 covers the literature available on production methods of metal foam and its limitations has been listed out. And conventional methods of manufacturing open cell metal foam heat exchangers and its disadvantages have been explained in detailed. Chapter 3 covers in detail the novel method of production and fabrication of open cell metal foam heat exchangers. Chapter 4 includes an experimental study, where thermal performance of heat exchangers has been assessed through heat transfer experiments. Chapter 5 is the conclusions and future works.

Nowadays numerical simulations are used to optimize manufacturing process. These numerical simulations need a large amount of input parameters and some of these parameters have not been sufficiently described. One of this parameter is thermal contact resistance, which is not sufficiently described for high temperatures and high contact pressure. This work describes experimental measuring of thermal contact resistance and how to determine thermal contact conductance which can be used as a boundary condition for numerical simulations. An Experimental device was built in Heat Transfer and Fluid Flow Laboratory, part of Brno University of Technology, and can be used for measuring thermal contact conductance in various conditions, such as contact pressure, initial temperatures of bodies in contact, type of material, surface roughness, presence of scales on the contact surface. Bodies in contact are marked as a sensor and a sample, both are embedded with thermocouples. The temperature history of bodies during an experiment is measured by thermocouples and then used to estimate time dependent values of thermal contact conductance by an inverse heat conduction calculation. Results are summarized and the dependence of thermal contact conductance in various conditions is described.

Current methods for measuring energy flow rate in a pipe use a variety of invasive sensors, including temperature sensors, turbine flow meters, and vortex shedding devices. These systems are costly to buy and install. A new approach that uses non-invasive sensors that are easy to install and less expensive has been developed. A thermal interrogation method using heat flux and temperature measurements is used. A transient thermal model, lumped capacitance method LCM, before and during activation of an external heater provides estimates of the fluid heat transfer coefficient ℎ and fluid temperature. The major components of the system are a thin-foil thermocouple, a heat flux sensor (PHFS), and a heater. To minimize the thermal contact resistance 𝑅" between the thermocouple thickness and the pipe surface, two thermocouples, welded and parallel, were tested together in the same set-up. Values of heat transfer coefficient ℎ, thermal contact resistance 𝑅", time constant 𝜏, and the water temperature °C, were determined by using a parameter estimation code which depends on the minimum root mean square 𝑅𝑀𝑆 error between the analytical and experimental sensor temperature values. The time for processing data to get the parameter estimation values is from three to four minutes. The experiments were done over a range of flow rates (1.5 gallon/minute to 14.5 gallon/minute). A correlation between the heat transfer coefficient ℎ and the flow rate 𝑄 was done for both the parallel and the welded thermocouples. Overall, the parallel thermocouple is better than the welded thermocouple. The parallel thermocouple gives small average thermal contact resistance 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑅"=0.00001 (𝑚2.°C/𝑊), and consistence values of water temperature and heat transfer coefficient ℎ, with good repeatability and sensitivity. Consequently, a non-invasive energy flow rate meter or (BTU) meter can be used to estimate the flow rate and the fluid temperature in real life. / MS / Today, the measuring energy flow rate, measuring flow rate and the fluid temperature, in a pipe is crucial in many engineering fields. In addition, there has been increased use of energy flow rate meters in the renewable energy system and other applications such as solar thermal and geothermal to estimate the useful thermal energy. Some of the commercial energy flow rate meters are using an invasive sensor, has to be inside the pipe, including turbine flow meter and vortex shedding device. These systems are expensive and difficult to install. A new approach that uses non-invasive sensors, attached on the outside of the pipe, that are easy to install and less expensive has been developed by using the heat flux and temperature measurements. A parameter estimation routine was used to analyze the data which depends on the minimum root mean square 𝑅𝑀𝑆 error between the calculated and experimental temperature values. A correlation between the unknown parameter, heat transfer coefficient (ℎ), and the measured flow rate 𝑄 was done to estimate the flow rate. The results show that the new non-invasive system has good repeatability, 15.45%, high sensitivity, and it is easy to install. Consequently, a non-invasive energy flow rate meter or (BTU) meter can be used to estimate the flow rate and the fluid temperature in real life.

This work presents the development of a novel and non-invasive method that measures fluid flow rate and temperature in pipes. While current non-invasive flow meters are able to measure pipe flow rate, they cannot simultaneously measure the internal temperature of the fluid flow, which limits their widespread application. Moreover, devices that are able to determine flow temperature are primarily intrusive and require constant maintenance, which can shut down operation, resulting in downtime and economic loss. Consequently, non-invasive flow rate and temperature measurement systems are becoming increasingly attractive for a variety of operations, including for use in leak detection, energy metering, energy optimization, and oil and gas production, to name a few. In this work, a new solution method and parameter estimation scheme are developed and deployed to non-invasively determine fluid flow rate and temperature in a pipe. This new method is utilized in conjunction with a sensor-based apparatus--"namely, the Combined Heat Flux and Temperature Sensor (CHFT+), which employs simultaneous heat flux and temperature measurements for non-invasive thermal interrogation (NITI). In this work, the CHFT+ sensor embodiment is referred to as the British Thermal Unit (BTU) Meter. The fluid's flow rate and temperature are determined by estimating the fluid's convection heat transfer coefficient and the sensor-pipe thermal contact resistance. The new solution method and parameter estimation scheme were validated using both simulated and experimental data. The experimental data was validated for accuracy using a commercially available FR1118P10 Inline Flowmeter by Sotera Systems (Fort Wayne, IN) and a ThermaGate sensor by ThermaSENSE Corp. (Roanoke, VA). This study's experimental results displayed excellent agreement with values estimated from the aforementioned methods. Once tested in conjunction with the non-invasive BTU Meter, the proposed solution and parameter estimation scheme displayed an excellent level of validity and reliability in the results. Given the proposed BTU Meter's non-invasive design and experimental results, the developed solution and parameter estimation scheme shows promise for use in a variety of different residential, commercial, and industrial applications. / MS / This work documents the development of a novel and non-invasive method that measures fluid flow rate and temperature in pipes. While current non-invasive flow meters are able to measure pipe flow rate, they cannot simultaneously measure the internal temperature of the fluid flow, which limits their widespread application. Moreover, devices that are able to determine flow temperature are primarily intrusive and require constant maintenance, which can shut down operation, resulting in downtime and economic loss. Consequently, non-invasive flow rate and temperature measurement systems are becoming increasingly attractive for a variety of operations, including for use in leak detection, energy metering, energy optimization, and oil and gas production, to name a few. This paper presents a new method that utilizes a non-invasive British Thermal Unit (BTU) Meter based on Combined Heat Flux and Temperature Sensor (CHFT+) technology to determine fluid flow rate and temperature in pipes. The non-invasive BTU Meter uses thermal interrogation to determine different flow parameters, which are used to determine the fluid flow rate and temperature inside a pipe. The method was tested and validated for accuracy and reliability through simulations and experiments. Given the proposed BTU Meter’s noninvasive design and excellent experimental results, the developed novel sensing method shows promise for use in a variety of different residential, commercial, and industrial applications.

Τα δομικά στοιχεία των μηχανολογικών κατασκευών υπόκεινται σε επαναλαμβανόμενες κυκλικές καταπονήσεις, από τις οποίες δημιουργούνται και διαδίδονται ρωγμές. Οι καταπονήσεις αυτές, οι οποίες προκαλούν κόπωση στις κατασκευές, μπορεί να είναι είτε καθαρά μηχανικές είτε θερμικές ή να προκύπτουν σα συνδυασμός θερμικής και μηχανικής φόρτισης. Τυπικές περιπτώσεις θερμικών και θερμομηχανικών φορτίσεων εμφανίζονται σε κατασκευές, όπως σωλήνες κυκλωμάτων ψύξης, πιεστικά δοχεία, συνιστώσες ηλεκτρικών κυκλωμάτων, θάλαμοι μηχανών εσωτερικής καύσης και πτερύγια στροβιλοκινητήρων. Η κυκλική μεταβολή του θερμικού φορτίου στις προαναφερθείσες περιπτώσεις, συνιστά συνθήκες θερμικής κόπωσης. Επίσης, λόγω της σχετικά υψηλής συχνότητας του φορτίου η θερμοκρασία παρουσιάζει έντονη μεταβολή στο χώρο και στο χρόνο. Ο προσδιορισμός της διάρκειας ζωής ενός δομικού στοιχείου κατά τη φάση του σχεδιασμού μπορεί να γίνει με τη βοήθεια πειραματικών διαδικασιών. Τα πειράματα όμως κόπωσης είναι δαπανηρά και χρονοβόρα και προφανώς απαιτούνται περισσότερες από μια πειραματικές δοκιμές. Οπότε, είναι εύλογο να υπάρχουν υπολογιστικά εργαλεία που να δίνουν τη δυνατότητα στο μηχανικό να εκτιμήσει την διάρκεια ζωής ή τη σοβαρότητα της βλάβης ενός εξαρτήματος. Τα περισσότερα υπολογιστικά μοντέλα αναφέρονται σε καθαρά μηχανικές καταπονήσεις. Έτσι υπάρχει πρόσφορο έδαφος για την ανάπτυξη υπολογιστικών εργαλείων για την ανάλυση προβλημάτων θερμικής και θερμομηχανικής κόπωσης. Τέτοιου είδους εργαλεία θα πρέπει να λαμβάνουν υπόψη το κλείσιμο των ρωγμών, που συμβαίνει λόγω των θερμικών παραμορφώσεων, διότι είναι δυνατόν να επηρεάζεται τοπικά το θερμοκρασιακό πεδίο. Επομένως, χρειάζεται επαναληπτική διαδικασία για τον προσδιορισμό του θερμικού και τασικού πεδίου που αλληλεπιδρούν. Είναι προφανές ότι η ανάλυση της θερμικής κόπωσης εξελίσσεται σε συνθέτη διαδικασία, που θα πρέπει να συμπεριλαμβάνει τον υπολογισμό της κατανομής της θερμοκρασίας, την τοπική επίδραση του άκρου της ρωγμής στο τασικό πεδίο καθώς και την επαφή των επιφανειών της ρωγμής. Η μέθοδος των συνοριακών στοιχείων είναι ικανή να αντιμετωπίζει τέτοιου είδους τοπικές επιδράσεις. Η παρούσα διατριβή επικεντρώνεται στην ανάπτυξη υπολογιστικού εργαλείου βασισμένου στα συνοριακά στοιχεία, για την πρόβλεψη της διάδοσης ρωγμών και την εκτίμηση της διάρκειας ζωής, εξαρτημάτων υπό θερμική και θερμομηχανική κόπωση. Έμφαση δίνεται σε περιπτώσεις που το θερμικό φορτίο προκαλεί κλείσιμο της ρωγμής και σε περιπτώσεις διεπιφανειακών ρωγμών, όπου το θερμοκρασιακό πεδίο επηρεάζεται από την θερμική αντίσταση ανάμεσα στις επιφάνειες της ρωγμής. Στο πρώτο κεφάλαιο γίνεται βιβλιογραφική ανασκόπηση σε εργασίες που εστιάζουν σε φαινόμενα κόπωσης και διάδοσης ρωγμών, καθώς και στην ανάπτυξη υπολογιστικών μοντέλων για την πρόβλεψη της διάδοσης ρωγμών. Επιπλέον, προσδιορίζεται λεπτομερώς το αντικείμενο της παρούσας διατριβής και εξηγείται η συνεισφορά της και τα καινοτόμα σημεία της. Στο δεύτερο κεφάλαιο περιγράφεται η ιδιόμορφη συμπεριφορά του άκρου της ρωγμής, δίνονται οι διατυπώσεις των μεγεθών θραύσης που χρησιμοποιούνται στην ανάλυση της κόπωσης και αναφέρονται τρόποι με τους οποίους μελετάται η διάδοση ρωγμών. Στο τρίτο κεφάλαιο περιγράφονται λεπτομερώς οι ολοκληρωτικές συνοριακές διατυπώσεις για την επίλυση προβλημάτων θερμοελαστικότητας. Στο τέταρτο κεφάλαιο περιγράφονται οι υπολογιστικές διαδικασίες που ακολουθούνται στην παρούσα εργασία για τον προσδιορισμό του πεδίου θερμοκρασιών και μετατοπίσεων, καθώς και ο τρόπος που προσομοιώνεται η διάδοση ρωγμής. Στο πέμπτο κεφάλαιο παρατίθενται τα αποτελέσματα που προέκυψαν από τις αναλύσεις για διάφορες περιπτώσεις, ενώ στο έκτο κεφάλαιο εξάγονται συμπεράσματα και διατυπώνονται προτάσεις για μελλοντική έρευνα. / The prediction of fatigue life is essential for the integrity and reliability of a structure when designing engineering components that undergo cyclic loading. In most cases, the mechanical cyclic loads are taken into account in order to evaluate the life and damage tolerance of structures with existing cracks. However, there exists a category of structures that experience severe thermal cycling that acts alongside the mechanical loads. Such structures include cooling system pipes, pressure vessels, pistons and combustion chambers of internal combustion engines, gas turbine blades and components of electrical circuits. Interfacial crack growth is of paramount importance when designing components that are protected by thermal barrier coatings in order to increase their endurance and efficiency. These types of structures are exposed to very intense thermo-mechanical cycling, which gradually causes delamination and eventually leads to spallation of the coating Numerical simulations, via the finite element method, are a common trend, when analysing the endurance of coated components. However, important aspects such as the heat exchange between the contacting faces and friction are not taken into account in fracture assessments of these components. The boundary element method is very attractive for crack-growth analyses because only the boundary is meshed, rather than the whole domain of the problem. In the present thesis, the boundary integral equations of uncoupled, time-dependent thermo-elasticity are employed to account for the time-varying nature of the thermal load. Our study discusses the influence of crack closure on quasi-static, sub-critical crack extension in the presence of thermo-mechanical cyclic loading. Appropriate thermal and mechanical boundary conditions are imposed on the numerical model to account for the contact state. The validity of the code to compute the temperature distribution under thermal cycling is checked through analytical solutions. Afterwards, a pure mode-I and mixed mode fracture problems in homogeneous material are analysed and the results are compared to other boundary element solutions. The singularity resulting from tractions and heat flux around the crack tip is effectively captured by singular quarter-point elements, while the fracture magnitudes can be computed using appropriate traction formulas. In these problems, the fatigue life is evaluated in terms of load cycle when the crack closure is considered. The number of cycles required for an existing crack to grow a certain length can be empirically predicted using the Paris’ law. The crack extension angle is evaluated by means of the maximum circumferential stress. The results are discussed, clearly indicating the impact of crack closure on fatigue life evaluation. The main conclusion is that crack closure should be incorporated into the analysis whenever the contact effect is inevitable. Otherwise, the fatigue life may be underestimated, leading to a conservative design. Finally, the sub-domain boundary element procedure is applied to interfacial cracks where the crack closure is more pronounced. Specifically, a case of a thermal barrier coating system is investigated. The thermal resistance between the contacting crack faces is incorporated into the procedure and it is assumed to be dependent on the contact pressure. If crack closure due to thermal distortion takes place, then the displacement and traction field may affect the heat flux between the crack faces, and the thermal and mechanical parts of the problem will need to be solved repeatedly until thermo-mechanical convergence is achieved. The results suggest that there are significant effects on the behaviour of stably growing cracks and the evaluation of failure capacity, emanating from crack closure, the amount of thermal resistance and the phase angle between the mechanical and thermal loads.

Durant ces quarante dernières années, les Tubes à Ondes Progressives (TOP) n’ont cessé de se développer, orienté par la demande croissante des nouvelles applications (Internet Haut débit, TV HD…). Cette demande croissante en fréquence et en puissance se traduit par des problèmes d’échauffement thermique. En effet, l’augmentation de la puissance de sortie augmente la puissance dissipée. De plus, la montée en fréquence nécessite une diminution des dimensions, qui conduit tout logiquement à des densités de puissance plus importantes. Cette chaleur produite doit être évacuée par des petites surfaces de contact qui dépendent fortement du type d’assemblage. Cet échauffement thermique implique également des changements du comportement mécanique. Dans ce travail de thèse, le point principal a été l’étude du comportement des interfaces dans les tubes à ondes progressive. Il est question d’étudier les interfaces thermomécaniques produites lors de l'assemblage (frettage à chaud). L’objectif est de fournir un modèle de détermination de la température d’hélice en fonctionnement. Compte tenu des configurations de fonctionnement (Vide, haute tension, petite dimension…) une mesure directe n’est pas réalisable. Néanmoins plusieurs méthodes de mesure indirectes ont été investiguées afin de trouver la plus appropriée. Cette étude porte dans un premier temps sur les lignes de transmissions puis sur les collecteurs des TOPs. Nous avons réalisé un modèle analytique purement thermique permettant d’identifier rapidement l’impédance thermique des dispositifs. Une mesure de RTC et une coupe métallographique déterminant les surfaces de contact alimente ce modèle afin de lui donner une meilleure précision. Un modèle élément finis 2D nous permet d’identifier une pression moyenne de contact afin d’utiliser la RTC correspondante.L’impédance thermique, nous permet de trouver la température d’hélice en indiquant la puissance dissipée dans la ligne. / During these last forty years traveling Waves tubes did not stop developing directed by the increasing request of the new applications (High-speed Internet, TV HD). This increasing request in frequency and in power is translated by thermal heating problems. Indeed, the more the output power will be high, the more there will be of the dissipated power, with smaller and smaller size. This leads logically to bigger and bigger power densities. This produced heat must be evacuated by small contact areas, which depend strongly on the type of assembly. This thermal heating also involves changes of the mechanical behaviour. The principal point will be the study of the behaviour of the interfaces in traveling waves tubes. Thesis work, we study the thermal and mechanical interfaces produced during a hot shrinking. Goal of this work is to supply a numerical or analytical model of helix temperature determination with functioning. Considering the configurations of functioning (Vacuum, high-voltage, small dimension) a direct measure is not impossible. Nevertheless several indirect measure methods were investigated to find the most appropriate. This study concerns at first the transmissions lines then the collectors of TOPS. We realized an analytical thermal model allowing to identify quickly the thermal impedance of devices. A thermal contact resistance measurement and a metallographic cutting determining the contact areas feeds this model to give it a better precision. A 2D finite element allows us to identify an average pressure of contact to use the corresponding RTC. The thermal resistance, allows us to find the helix temperature by indicating the power dissipated in the line.

De nos jours, le contexte de mondialisation des marchés impose aux industriels des contraintes économiques sans précédent. Afin de rester concurrentiels, ils n’ont d’autre choix que de modifier leur façon de concevoir et d’innover. Les techniques de production sont directement concernées avec par exemple une volonté de réduire les cycles de mise au point visant à définir les paramètres optimaux de mise en forme. On constate alors l’immersion d’un besoin fort en moyens de support, flexibles et prédictifs, permettant de limiter les campagnes d’essais et de faciliter leur exploitation. La simulation numérique se présente comme un outil pouvant répondre à ces critères. Ce travail s’est inscrit dans une démarche d’amélioration de la modélisation et de la simulation des opérations d’usinage, et à une échelle plus locale, de la modélisation de la coupe des métaux. Il aborde donc un problème complexe, fortement couplé, faisant intervenir mécanique, thermique, tribologie et métallurgie dans des conditions extrêmes. Une première partie expérimentale s’est donc orientée vers une compréhension plus fine des mécanismes de coupe mis en jeu en usinage d’un C45 normalisé et d’un 42CrMo4 trempé revenu. Elle a notamment permis de mettre en évidence, dans les zones de déformation intense, des affinements de grain conséquents, produits par l’activation d’un processus de recristallisation dynamique (DRX). L’inspection des zones de contact outil-matière a également montré les fortes hétérogénéités de contact existantes à l’interface outil-copeau et révélant la formation d’une résistance thermique de contact. Une étude rhéologique des deux nuances s’est appuyée sur des essais de compression dynamique. Menée à haute déformation, elle a permis de reproduire les évolutions microstructurales observées en coupe et d’appréhender leur influence sur la limite d’écoulement des matériaux. Deux modèles de comportement "à base métallurgique" ont été identifiés, présentant une retranscription plus fidèle que les modèles phénoménologiques standards. Des essais tribologiques dédiés ont permis d’extraire des modèles de contact capables de reproduire les phénomènes locaux existants à l’interface outil-matière. L’accent s’est principalement porté sur la thermique de contact au travers de lois de partage variables intégrant la notion de résistance thermique. L’intégralité de ces modèles a enfin été implémentée dans le code de calcul Abaqus© grâce à des développements spécifiques. Une stratégie de modélisation a été mise en place autour d’un modèle de coupe 2D afin de restituer les tendances majeures observées lors de la coupe d’aciers spéciaux. L’association de modèles 2D et 3D à copeau continu, de modèles à copeau segmenté ainsi que de simulations thermiques découplées présente un fort potentiel permettant, à terme, de modéliser une opération d’usinage dans sa globalité. / Nowadays, in a context of globalization, companies are submitted to unprecedented economic constraints. To remain competitive, they are forced to change their way of designing and innovating. Manufacturing is directly concerned with in mind to reduce the development steps necessary to define the optimal processing parameters. A need of flexible and predictive support tools is clearly rising in order to limit the experimental campaigns and make easier their exploitation. The numerical simulation appears as a relevant tool that match these criteria. This work is a contribution to an approach which aims at improving the modeling and simulation of machining operations, and on a more local scale, the modeling of metal cutting. It therefore addresses a complex and tightly coupled problem, involving mechanics, thermal sciences, metallurgy and tribology in extreme conditions. A first experimental part was thus directed towards a more sophisticated understanding of the cutting mechanisms occuring in machining of a normalized AISI 1045 and a quenched and tempered AISI 4140. It made possible to highlight, in the main intensive deformation zones, drastic grain refinements produced by the activation of dynamic recrystallization (DRX). Inspection of the tool-material contact areas also showed the strong heterogeneities of contact existing at the tool-chip interface, revealing the formation of a thermal contact resistance. A rheological study of these two grades was based on dynamic compression tests. Conducted at high strain, it reproduced the microstructural changes observed in cutting and enabled to understand their influence on the flow stress of both materials. Two "metallurgy based" models have been identified, leading to a better description of the material behaviour than standard phenomenological models. Special tribological tests have been conducted and analyzed to extract contact models able to reproduce local phenomena existing at the tool-material interface. The study has especially been focused on the thermal contact through heat partition models including the concept of thermal contact resistance. The proposed constitutive and contact models were finally implemented in a finite element code Abaqus© thanks to some specific developments. A modeling strategy has been developed around a 2D cutting model in order to simulate the major trends observed during the cutting of the mentioned steels. The combination of 2D and 3D continuous chip models, 2D segmented models and uncoupled thermal simulations appears as promising to model the different aspects of a machining operation.