The goal of this line of research is to add to the existing body of literature on the effect of heat treatments on the microstructure of chrome-bearing white irons and add bend test data to the literature concerning chrome-bearing white irons. This project was intended to support an existing line of research into cast metal-ceramic lattices using chrome white iron as a substitute for sintered ceramic tiles used to defeat projectiles. Chrome-bearing white irons have a substantial quantity of chromium carbides, giving them high hardness and abrasion resistance. Additionally, tiles cast from white iron proved to be more durable than sintered ceramic tiles, breaking into large chunks rather than a powder following an impact. These properties make tiles cast from chrome-bearing white iron a low-cost alternative to sintered carbides. The alloy investigated contained nominally 14 chromium and 3.2 carbon by weight percent. Three-point bend test specimens were cut from cast plates. These specimens were austenitized, air cooled, then tempered prior to three-point bend and hardness testing. The microstructure of the specimens was evaluated using optical microscopy, SEM, and XRD. This line of research revealed that lower austenitization temperatures resulted in a martensitic matrix with fewer, smaller secondary carbides, resulting in higher strength and hardness. In contrast, higher austenitization temperatures produced an austenitic matrix with coarser carbides, resulting in lower strength and hardness. This research did not reveal an appreciable change in ductility over heat treatment temperature. / Master of Science / This research investigates a hard iron alloy capable of replacing expensive ceramics in situations where the goal is to prevent penetration by a projectile. This iron alloy, known as white cast iron, can be cast using typical foundry practices, making it cost-effective. Additionally, the properties can be changed by heat-treatment, a process that involves heating the material to a given temperature, holding it at that temperature for a given amount of time, then cooling the material at a given rate. The results of this research add to the existing understanding of how heat treatment affects the properties of white cast iron. Additionally, this research generated new data about the strength of white cast irons in a three-point bending test, a test not normally used for white cast irons. The research found that high heat-treatment temperatures resulted in a softer white cast iron with lower strength. The structure of the white cast iron treated at these temperatures was predominantly austenite, a soft iron phase, and large carbides, a hard but brittle phase. Temperatures close to the lower end of the temperature range tested resulted in a harder white cast iron with higher strength. The structure of the iron in these conditions contained martensite, a hard iron phase, some austenite, and smaller but more angular carbides.

The use of composite sandwich structures is rapidly increasing in the aerospace industry because of their increased strength-to-weight and stiffness-to-weight characteristics. The effects of low velocity impacts on these structures, however, are the main weakness that hinders further use of them in the industry because the damages from these loadings can often be catastrophic. Impact behavior of composite materials in general is a crucial consideration for a designer but can be difficult to describe theoretically. Because of this, experimental analysis is typically used to attempt to describe the behavior of composite sandwiches under impact loads. Experimental testing can still be unpredictable, however, because low velocity impacts can cause undetectable damage within the composites that weaken their structural integrity. This is an important issue with composite sandwich structures because interlaminar damage within the composite facesheets is typical with composites but the addition of a core material results in added failure modes. Because the core is typically a weaker material than the surrounding facesheet material, the core is easily damaged by the impact loads. The adhesion between the composite facesheets and the core material can also be a major region of concern for sandwich structures. Delamination of the facesheet from the core is a major issue when these structures are subjected to impact loads. This study investigated, through experimental and numerical analysis, how varying the core and facesheet material combination affected the flexural strength of a composite sandwich subjected to low velocity impact. Carbon, hemp, aramid, and glass fiber materials as facesheets combined with honeycomb and foam as core materials were considered. Three layers of the same composite material were laid on the top and bottom of the core material to form each sandwich structure. This resulted in eight different sandwich designs. The carbon fiber/honeycomb sandwiches were then combined with the aramid fiber facesheets, keeping the same three layer facesheet design, to form two hybrid sandwich designs. This was done to attempt to improve the impact resistance and post-impact strength characteristics of the carbon fiber sandwiches. The two and one layer aramid fiber laminates on these hybrid sandwiches were always laid up on the outside of the structure. The sandwiches were cured using a composite press set to the recommended curing cycle for the composite facesheet material. The hybrid sandwiches were cured twice for the two different facesheet materials. The cured specimens were then cut into 3 inch by 10 inch sandwiches and 2/3 of them were subjected to an impact from a 7.56 lbf crosshead which was dropped from a height of 38.15 inches above the bottom of the specimen using a Dynatup 8250 drop weight machine. The impacted specimen and the control specimen (1/3 of the specimens not subjected to an impact) were loaded in a four-point bend test per ASTM D7250 to determine the non-impacted and post-impact flexural strengths of these structures. Each sandwich was tested under two four-point bend loading conditions which resulted in two different extension values at the same 100 lbf loading value. The span between the two supports on the bottom of the sandwich was always 8 inches but the span between the two loading pins on the top of the sandwich changed between the two loading conditions. The 2/3 of the sandwiches that were tested after being impacted were subjected to bending loads in two different ways. Half of the specimens were subjected to four-point bending loads with the impact damage on the top facesheet (compressive surface) in between the loading pins; the other half were subjected to bending loads with the damage on the bottom facesheet (tensile surface). Theoretical failure mode analysis was done for each sandwich to understand the comparisons between predicted and experimental failures. A numerical investigation was, also, completed using Abaqus to verify the results of the experimental tests. Non-impacted and impacted four-point bending models were constructed and mid-span deflection values were collected for comparison with the experimental testing results. Experimental and numerical results showed that carbon fiber sandwiches were the best sandwich design for overall composite sandwich bending strength; however, post-impact strengths could greatly improve. The hybrid sandwich designs improved post-impact behavior but more than three facesheet layers are necessary for significant improvement. Hemp facesheet sandwiches showed the best post-impact bending characteristics of any sandwich despite having the largest impact damage sizes. Glass and aramid fiber facesheet sandwiches resisted impact the best but this resulted in premature delamination failures that limited the potential of these structures. Honeycomb core materials outperformed foam in terms of ultimate bending loads but post-impact strengths were better for foam cores. Decent agreement between numerical and experimental results was found but poor material quality and high error in material properties testing results brought about larger disagreements for some sandwich designs.

This thesis discusses how to test the mechanical properties of openlattice truss structures and hybrids being a tube containing a latticetruss structure. By properties we mean strength, stiffness, thermalconductivity and so forth.Mechanical testing was done on two different structures to betterunderstand how the load-bearing properties change when these structuresare subjected to tensile, compressive and bending forces. The structuresinvestigated were Diamond and Octagon built at 45° and 90°. Acousticemission was also used to evaluate and analyze the different behaviour ofthe structures. The test results were used to produce design criteria forproperties in different cell structures manufactured of Hastelloy X™. Amap with design criteria containing stiffness and weight per cubiccentimetre was produced for parts that would be subjected to compressiveforces.

This thesis was most concerned with the mechanical response to irradiation of two in-house produced oxide dispersion strengthened (ODS) steels and two non-ODS coun- terparts. The steels, manufactured by Dr. M. J. Gorley (University of Oxford), were me- chanically alloyed from gas-atomised Fe-14Cr-3W-0.2Ti, with the addition of 0.25Y₂O₃ powder in the case of the ODS variants. The powders were hot isostatic pressed at consolidation temperatures of 950 °C and 1150 °C. The four steels were designated 14WT 950 (non-ODS), 14YWT 950 (ODS), 14WT 1150 (non-ODS) and 14YWT 1150 (ODS), and were used in the as-produced condition. Initially, the macroscale elastic modulus and yield stress were determined using a four-point flexure test, employing digital image correlation (DIC) as a strain gauge. The microcantilever size eects were then characterised, and it was determined that the yield stress signicantly diverged from macroscale values at microcantilever beam depths of < 4.5 μm. Using knowledge of this, the in-house produced alloys were irradiated with 2 MeV protons at the Surrey Ion Beam Centre (University of Surrey, UK) to a displacement damage of ∼ 0.02 dpa and 0.2 dpa (Bragg peak). This was to produce a deep irradiated layer for the fabrication of large microcantilevers with reduced size effects. The cross-sectional surface of the irradiated layer was then exposed and inclined linear arrays of 250 nm deep indents were placed across the damage prole. 14WT 1150 (non-ODS) revealed a clear proton damage prole in plots of hardness against irradiation depth, 14WT 950 (non-ODS) also showed modest hardening in the region of the Bragg peak. No appreciable hardening was observed in either 14YWT specimens, attributed to the fine dispersion of nanoscale oxides providing a high number density of defect sink sites. However, a large bimodal variation in hardness was measured in both ODS variants. This was investigated using EBSD and EDX, and was determined to be caused by a pronounced heterogeneity of the microstructure. While Hall-Petch strengthening and changes in the local chemistry had some effect on the measured hardness, the most likely cause of the large variation in local hardness was heterogeneity in the nanoscale oxide population. Microcantilevers were fabricated out of the irradiated layer cross-section in 14WT 1150 and 14YWT 1150. Larger microcantilevers, with ∼ 5 μm beam depth, were placed with their beam centre at ∼ 0.026 dpa. Smaller microcantilevers, with ∼ 1.5 μm beam depth, were placed with their beam centre at the Bragg peak, 0.2 dpa. Both the large and the small microcantilevers fabricated in 14WT 1150 (non-ODS) displayed significant irradiation hardening. In the ODS variant, 14YWT 1150, irradiation hardening appeared to be reduced. The work in this thesis successfully showed that it was possible to extract a close approximation of the macroscale yield stress from shallow irradiated layers, providing that the irradiation condition is carefully chosen in response to known size dependent behaviour. This thesis also investigated the size dependent behaviour of microcantilevers using a lengthscale dependent crystal plasticity UMAT, developed by Dunne et al. and implemented within ABAQUS 6.14-2 commercially available nite element software. The simulation of the GND density evolution with increasing plastic strain allowed their contribution to the microcantilever size effect, through mobile dislocation pinning, to be determined. This novel approach to modelling size effects in three dimensional finite element microcantilever models demonstrated that while it was possible to simulate a lengthscale-dependent response in finite element microcantilever models, the constitutive equation for the plastic velocity gradient needs to be more physically based in order the match the experimentally derived results; for example, a lengthscale-dependent term relating to the dislocation source density of the material. Although the apparent reduction of irradiation hardening in ODS in-house produced alloys showed great promise, these alloys also displayed a large amount of scatter in measured hardness and yield stress, attributed to the pronounced heterogeneity in the microstructure. Alloys with such signicant microstructural heterogeneity are not suitable for engineering or commercial use.