Magma chambers are a fundamental component of crustal magma transport modulating erupted volumes, compositions, and timing of eruptions. However, we understand little about how eruption episodicity relates to magma chamber evolution. A sizable amount of research has been done on the thermo-mechanical and chemical evolution of a chamber, but little has been done in combining the two. The many influences on composition make inference of crustal processes from erupted compositions dicult, but there are patterns of eruptive evolution in well- characterized systems that suggest something systematic is occurring. We have developed a coupled thermo-mechanical-chemical model in order to characterize melt evolution through cycles of chamber filling, rupture, and drainage in a thermally evolving, viscoelastic crust. We consider a deeply seated oblate spheroidal chamber, calculating pressure, temperature, volume, elemental concentration, partitioning between crystals and melt, and crustal temperature through time. We characterize the time dependence of chamber failure, thermal longevity, and melt elemental concentrations on mechanical parameters and influx rates, exploring the dependence on depth, primary and crustal compositions. These results should be important for constraining physical controls on eruption episodicity and predictions of instability at magmatic centers.

Multilayer embedded passives (resistors, inductors, and capacitors) on a printed wiring board can help to meet high performance requirements at a low cost and at a smaller size. Such an integration of embedded passives has new challenges with respect to design, materials, manufacturing, thermal management and reliability. As the area of integral passives on printed circuit boards is relatively new, there is inadequate literature on the thermo-mechanical reliability of integral passives. Therefore, there is a compelling need to understand the thermo-mechanical reliability of integral passives through the development of physics-based models as well as through experiments, and this thesis aims to develop such an experimental and theoretical program to study the thermo-mechanical reliability of integral passives.. As integral passives are often composite layers with dissimilar material properties compared to the other layers in the integral substrate, it is essential to ensure that RLC characteristics of the embedded passives do not deteriorate with thermal cycling due to thermo-mechanical deformations. This thesis aims to study the changes in the passive characteristics due to the thermally-induced deformations. Embedded capacitors and inductors have been looked at specifically in this research. Multi-field physics-based models have been constructed to determine the change in electrical parameters after thermal cycling. The thermo-mechanical models assume direction-dependent material properties for the board substrate and interconnect copper layers and temperature-dependent properties for interlayer dielectric and passive layers. Using the deformed geometry, the electrical characteristics have been determined at low frequency. In parallel to the models, test vehicle substrates have been subjected to 1000 thermal cycles between -55??o 125??nd high humidity and temperature conditions at 85??5RH for 500 hours, and it has been observed that there are significant changes in the electrical parameters. The results obtained from the physics-based simulations have been validated against the measured electrical characteristics from the fabricated functional test boards that have been thermal cycled.

A recursive-iterative algorithm is developed for predicting nonlinear viscoelastic behaviors of isotropic materials that belong to the thermorheologically complex material (TCM). The algorithm is derived based on implicit stress integration solutions within a general displacement based FE structural analyses for small deformations and uncoupled thermo-mechanical problems. A previously developed recursive-iterative algorithm for a stress-dependent hereditary integral model which was developed by Haj-Ali and Muliana is modified to include time-temperature effects. The recursive formula allows bypassing the need to store entire strain histories at each Gaussian integration point. Two types of iterative procedures, which are fixed point and Newton-Raphson methods, are examined within the recursive algorithm. Furthermore, a consistent tangent stiffness matrix is formulated to accelerate convergence and avoid divergence. The efficiency and accuracy of the proposed algorithm are evaluated using available experimental data and several structural analyses. The performance of the proposed algorithm under multi-axial conditions is verified with analytical solutions of creep responses of a plate with a hole. Next, the recursive-iterative algorithm is used to predict the overall response of single lap-joint. Numerical simulations of time-dependent crack propagations of adhesive bonded joints are also presented. For this purpose, the recursive algorithm is implemented in cohesive elements. The numerical assessment of the TCM and thermorheologically simple material (TSM) behaviors has also been performed. The result showed that TCM are able to describe thermo-viscoelastic behavior under general loading histories, while TSM behaviors are limited to isothermal conditions. The proposed numerical algorithm can be easily used in a micromechanical model for predicting the overall composite responses. Examples are shown for solid spherical particle reinforced composites. Detailed unit-cell FE models of the composite systems are generated to verify the capability of the above micromechanical model for predicting the overall nonlinear viscoelastic behaviors.

Fuel cells are the direct energy conversion devices which convert the chemical energy of a fuel to electrical energy with much greater efficiency than conventional devices. Solid Oxide Fuel Cell (SOFC) is one of the various types of available fuel cells; wherein the major components are made of inherently brittle ceramics. Planar SOFC have the advantages of high power density and design flexibility over its counterpart tubular configuration. However, structural integrity, mechanical reliability, and durability are of great concern for commercial applications of these cells. The stress distribution in a cell is a function of geometry of fuel cell, temperature distribution, external mechanical loading and a mismatch of thermo-mechanical properties of the materials in contact. The mismatch of coefficient of thermal expansion and elastic moduli of the materials in direct contact results in the evolution of thermal stresses in the positive electrode/electrolyte/negative electrode (PEN) assembly during manufacturing and operating conditions (repeated start up and shut down steps) as well. It has long been realized and demonstrated that the durability and reliability of SOFCs is not only determined by the degradation in electrochemical performance but also by the ability of its component materials to withstand the thermal stresses. In the present work, an attempt has been made to evaluate the thermal stresses as a function of thermal and mechanical properties of the component materials assuming contribution from other factors such as thermal gradient, mechanical loading and in-service loading conditions is insignificant. Materials used in the present study include the state of art anode (Ni-YSZ), electrolyte(YSZ) and cathode materials(LM and LSM) of high temperature SOFC and also the ones being suggested for intermediate temperature SOFC Ni-SCZ as an anode, GDC and SCZ as electrolyte and LSCF as the cathode. Variation of thermo-mechanical properties namely coefficient of thermal expansion, and elastic and shear moduli were studied using thermo-mechanical analyzer and resonant ultrasound spectroscope respectively in 25-900°C temperature range. A non-linear variation in elastic and shear moduli- indicative of the structural changes in the studied temperature range was observed for most of the above mentioned materials. Coefficient of thermal expansion (CTE) was also found to increase non-linearly with temperature and sensitive to the phase transformations occurring in the materials. Above a certain temperature (high temperature region- above 600°C), a significant contribution from chemical expansion of the materials was also observed. In order to determine thermal stress distribution in the positive electrode, electrolyte, negative electrode (PEN) assembly, CTE and elastic and shear moduli of the component materials were incorporated in finite element analysis at temperature of concern. For the finite element analysis, anode supported configuration of PEN assembly (of 100mm x 100mm) was considered with 1mm thick anode, 10μm electrolyte and 30μm cathode. The results have indicated that cathode and anode layer adjacent to cathode/electrolyte and electrolyte/anode interface respectively are subjected to tensile stresses at the operating temperature of HT-SOFC (900°C) and IT-SOFC (600°C). However, the magnitude of stresses is much higher in the former case (500MPa tensile stress in cathode layer) when compared with the stress level in IT-SOFC (178MPa tensile stress in cathode layer). These high stresses might have been resulted from the higher CTE of cathode when compared with the adjacent electrolyte. However, it is worth mentioning here that in the present work, we have not considered any contribution from the residual stresses arising from fabrication and the stress relaxation from softening of the glass sealant.

The topic of structural damage caused by fires following an earthquake (FFE) has been discussed extensively by many researchers for over a decade in order to bring the two fields closer together in the context of performance based structural engineering. Edinburgh University, Heriot-Watt University, Indian Institute of Technology Roorkee (IIT Roorkee) and Indian Institute of Science initiated a collaboration to study this problem under a UK-India Engineering Research Initiative (UKIERI) funded project. The first construction of a single-storey reinforced concrete frame at IIT Roorkee was completed in summer 2011; this is known as the Roorkee Frame Test 1 throughout this thesis. This thesis presents the modelling of the Roorkee Frame Test 1 using the finite element method and assesses the capability of the numerical methodologies for analysing these two sequential events. Both two and three dimensional finite element models were developed. Beam and shell elements were chosen for the numerical modelling, which was carried out using the general purpose finite element package ABAQUS (version 6.8). The variation in material properties caused by these two types of loading, including strength and stiffness degradation, compressive hardening, tension stiffening, and thermal properties, is implemented in the numerical modelling. Constitutive material calculations are in accordance with EC4 Part 1.1, and all loading is according to IS 1893:2002 Part 1 (Indian Standard). The time-temperature curve used in the analysis is based on data from the test carried out. The behaviour of the Roorkee Frame Test 1 when subjected to monotonic, cyclic lateral loading followed by fire is presented. The capacity of the frame when subjected to lateral loading is examined using a static non-linear pushover method. Incremental lateral loading is applied in a displacement-controlled manner to induce simulated seismic damage in the frame. The capacity curve, hysteresis loops and residual displacements are presented, discussed and compared with the test results. The heat transfer analysis using three dimensional solid elements was also compared against temperature distributions recorded during the Roorkee frame fire test. Based on the smoke layer theory, two emissivity values were defined. In this study, the suitability of numerical modelling using ABAQUS to capture the behaviour of Roorkee frame test is examined. The results from this study show that the 3D ABAQUS model predicted more reliable hysteresis curves compared to the 2D ABAQUS model, but both models estimated the lateral load capacity well. However neither model was able to simulate the pinching effect clearly visible in the hysteresis curves from the test. This was due to noninclusion of the bond slip effect between reinforcing bars and concrete. The residual displacement obtained at the end of the cyclic lateral loading analysis from the 2D ABAQUS model is higher than that seen in the test. However, the result in the 3D ABAQUS model matched the trend obtained in the test. The both columns appear to stiffen under the heating and the residual displacement seems to recover slightly. Lateral displacements, obtained in the thermo-mechanical analysis of the numerical models, show that thermal expansion brings the frame back towards its initial position. Finally, correlation studies between analytical and experimental results are conducted with the objective to establish the validity of the proposed model and identify the significance of various effects on the local and global response of fire resistance earthquake damaged of reinforced concrete frames. These studies show that the effect of tension stiffening and bond-slip are very important and should always be included in finite element models of the response of reinforced concrete frame with the smeared crack model when subjected to lateral and thermal loading. The behaviour of reinforced concrete frames exposed to fire is usually described in terms of the concept of the fire resistance which defined in terms of displacement limit. This study shows the global displacement of the frame subjected to fire recover slightly due to the thermal expansion during the heating.

This thesis is concerned with the design, analysis and optimisation of semi-solid or non- pneumatic tyres. More specifically, the thesis is intended to show how the FEA software package Abaqus can be used to determine whether or not an AirBoss tyre meets performance criteria in regards load/deformation criteria and if there is a likelihood of failure through overheating of the tyre during service.The work is intended to clearly explain the nature of natural rubber from a molecular description through to phenomenological descriptions used to solve for stresses, strains, creep and relaxation phenomena and temperature generation through hysteresis losses within the structure of the rubber compound.The thesis examines practical ways to obtain data for use in the analysis and describes test equipment (both "off-the-shelf" and purpose built) to obtain the required information.The objective is to progress, step by step, through the stages of analysis beginning with information to predict static loading conditions for the tyre. Viscoelastic behaviour, such as creep and relaxation are predicted and then tested to determine the correlation and refine test data before proceeding to the next stage of analysis.Ultimately, a prediction is made as to the temperature distribution throughout a section of the non-pneumatic tyre. A testing rig is described which has been built to test the analysis and enable a comparison to be made between FEA prediction and "real life".

Warm forming of aluminum alloys of has shown promising results for increasing the formability of aluminum alloy sheet. Warm forming is a term that is generally used to describe a sheet metal forming process, where part or all of the blank is formed at an elevated temperature of less than one half of the material’s melting temperature. The focus of this work is to study the effects of warm forming on Novelis X926 clad aluminum brazing sheet. Warm forming of clad aluminum brazing sheet, which is commonly used in automotive heat exchangers has not been studied. This work can be split into three main goals: i) to characterize the material behavior and develop a constitutive model, ii) to experimentally determine the effects of warm forming on deep drawing; and, iii) to create and validate a finite element model for warm forming of Novelis X926. For an accurate warm forming material model to be created, a temperature and rate dependant hardening law as well as an anisotropic yield function are required. Uniaxial isothermal tensile tests were performed on 0.5mm thick Novelis X926at 25°C (room temperature), 100°C, 150°C, 200°C, and 250°C. At each temperature, tests were performed with various strain rates between 7.0 E -4 /sec and 7.0 E -2 /sec to determine the strain rate sensitivity. Tensile tests were also performed at 0° (longitudinal), 45° (diagonal), and 90° (transverse) with respect to the material rolling direction in order to assess the anisotropy of the material. It was found that increasing forming temperature increases elongation to failure by 200%, decreases flow stress by 35%, and increases strain rate sensitivity. Barlat’s Yield 2000 yield function (Barlat et al., 2003a) and the Bergström work hardening law (van den Boogaard and Huétink , 2006) were found to accurately method model the material behavior. Warm deep drawing of 101.6 mm (4”) diameter cylindrical cups was performed using specially designed tooling with heated dies and a cooled punch. Deep drawing was performed on 228.6 mm (9“) and 203.2 mm (8”) diameter blanks of 0.5 mm thick Novelis X926. Deep drawing was performed with die temperatures ranging from 25°C to 300°C with a cooled punch. Teflon sheet and Dasco Cast 1200 lubricants were used in experiments. Different punch velocities were also investigated. 228.6 mm diameter blanks, which could not be drawn successfully at room temperature, were drawn successfully using 200°C dies. Increasing the die temperature further to 250°C and 300°C provided additional improvement in formability and reduced tooling loads. Increasing the punch velocity, increases the punch load when forming at elevated temperatures, reflecting the strong material rate sensitivity at elevated temperatures. A coupled thermal mechanical finite element model was developed using the Bergström hardening rule and the Yield 2000 yield surface using LS-DYNA. The model was found to accurately predict punch force for warm deep drawing using Teflon sheet as a lubricant. Results for Dasco Cast 1200 were not as accurate, due to the difficulties in modeling the lubricant’s behavior. Finite element simulations demonstrated that warm forming can be used to reduce thinning at critical locations, compared to parts formed at room temperature.

Dramatic advances are taking place in the microelectronic industry. The feature size continues to scale down and it is expected that the minimum feature size on the integrated circuit is expected to reach 9 nm by 2016, and there will be more than 8 billion transistors on a 310 cm² chip, according to various available roadmaps. Subsequently, this reduction in feature size would require the first-level input-output interconnects to decrease in pitch size to meet the increased number of transistors on the chip. Also, to minimize the on-chip interconnect delay, development of low-K dielectric/copper will become increasingly common in future devices. However, due to the low fracture strength of low-K dielectric, it is essential that the first-level interconnects exert minimal force on the die pads and therefore, do not crack or delaminate the low-K dielectric material. It is also preferable to have a wafer-level packaging approach to facilitate test-and-burn in and to produce known-good dies. Based on these growing demands from the microelectronics industry, there is a compelling need to develop innovative interconnect technologies. This thesis aims to develop one such innovative interconnect — G-Helix interconnect. G-Helix is a scalable lithography-based wafer-level electroplated compliant interconnect that has the potential to meet the fine-pitch first-level chip-to-substrate interconnect requirements. The three-mask fabrication of G-Helix is based on lithography, electroplating and molding (LIGA-like) technologies, and this fabrication can be easily integrated into large-area wafer-level fine-pitch batch processing. In this work, the fabrication, assembly, experimental reliability testing, and numerical physics-based modeling of the G-Helix interconnects will be presented. The fabrication of the interconnects will be demonstrated at 100μm pitch on a 20 x 20 mm die in a class 10/1000 cleanroom facility. The wafers with compliant interconnects will be singulated into individual dies and assembled on substrates using Pb/Sn eutectic solder. The assembly will then be subjected to air-to-air thermal cycling between 0℃and 100℃ and the reliability of the compliant interconnect will be assessed. In addition to the thermo-mechanical reliability testing, some of the dies with free-standing interconnects will also be used for measuring the compliance of the interconnects by compressing with a nanoindenter. In parallel to the experimental research, a numerical analysis study will also be carried out. The numerical model will use direction-, temperature, time-dependent, and time independent material constitutive properties as appropriate. The thermo-mechanical fatigue life of the compliant interconnect assembly will be determined and compared with the experimental data. Recommendations will be developed for further enhancement of reliability and reduction in pitch size.

Warm forming of aluminum alloys of has shown promising results for increasing the formability of aluminum alloy sheet. Warm forming is a term that is generally used to describe a sheet metal forming process, where part or all of the blank is formed at an elevated temperature of less than one half of the material’s melting temperature. The focus of this work is to study the effects of warm forming on Novelis X926 clad aluminum brazing sheet. Warm forming of clad aluminum brazing sheet, which is commonly used in automotive heat exchangers has not been studied. This work can be split into three main goals: i) to characterize the material behavior and develop a constitutive model, ii) to experimentally determine the effects of warm forming on deep drawing; and, iii) to create and validate a finite element model for warm forming of Novelis X926. For an accurate warm forming material model to be created, a temperature and rate dependant hardening law as well as an anisotropic yield function are required. Uniaxial isothermal tensile tests were performed on 0.5mm thick Novelis X926at 25°C (room temperature), 100°C, 150°C, 200°C, and 250°C. At each temperature, tests were performed with various strain rates between 7.0 E -4 /sec and 7.0 E -2 /sec to determine the strain rate sensitivity. Tensile tests were also performed at 0° (longitudinal), 45° (diagonal), and 90° (transverse) with respect to the material rolling direction in order to assess the anisotropy of the material. It was found that increasing forming temperature increases elongation to failure by 200%, decreases flow stress by 35%, and increases strain rate sensitivity. Barlat’s Yield 2000 yield function (Barlat et al., 2003a) and the Bergström work hardening law (van den Boogaard and Huétink , 2006) were found to accurately method model the material behavior. Warm deep drawing of 101.6 mm (4”) diameter cylindrical cups was performed using specially designed tooling with heated dies and a cooled punch. Deep drawing was performed on 228.6 mm (9“) and 203.2 mm (8”) diameter blanks of 0.5 mm thick Novelis X926. Deep drawing was performed with die temperatures ranging from 25°C to 300°C with a cooled punch. Teflon sheet and Dasco Cast 1200 lubricants were used in experiments. Different punch velocities were also investigated. 228.6 mm diameter blanks, which could not be drawn successfully at room temperature, were drawn successfully using 200°C dies. Increasing the die temperature further to 250°C and 300°C provided additional improvement in formability and reduced tooling loads. Increasing the punch velocity, increases the punch load when forming at elevated temperatures, reflecting the strong material rate sensitivity at elevated temperatures. A coupled thermal mechanical finite element model was developed using the Bergström hardening rule and the Yield 2000 yield surface using LS-DYNA. The model was found to accurately predict punch force for warm deep drawing using Teflon sheet as a lubricant. Results for Dasco Cast 1200 were not as accurate, due to the difficulties in modeling the lubricant’s behavior. Finite element simulations demonstrated that warm forming can be used to reduce thinning at critical locations, compared to parts formed at room temperature.

The single crystal superalloy PWA 1484 is used in hot section turbine blade applications due to its performance at high temperatures. In practice, the turbine blades are often coated in order to protect them from environmental degradation. However, under repeated cyclic loading, the coating may serve as a site for crack initiation in the blades. Fundamental out-of-phase (OP) thermo-mechanical fatigue (TMF) studies, primarily using uncoated solid cylindrical test samples, have previously examined both crack initiation and propagation in PWA 1484. In this work, mechanical strain-controlled OP TMF tests were performed on coated and uncoated specimens of a hollow cylindrical geometry in order to study the effects of both geometry and coating on the TMF crack initiation behavior. To accomplish this, it was necessary to create and analyze a modified gripping mechanism due to the unique geometry of the test samples, and as predicted by hand calculations and finite element analysis, these modifications proved to be successful. The TMF test results for the uncoated material were compared to those from previous studies under the same testing conditions, and it was found that the differences in geometry had a minimal impact on fatigue life. Comparisons of the results for the coated and uncoated material suggested that the coating may have offered a slight improvement in life, although insufficient results were available to determine whether these differences were statistically significant. Damage mechanisms resulting from different test conditions were also observed through microscopy on failed specimens.