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Yes / The shrinkage force exerted by restrained shape memory polymers can potentially be used to close cracks in structural concrete. This paper describes the physical processing and experimental work undertaken to develop high shrinkage die-drawn Polyethylene Terephthalate (PET) shape memory polymer tendons for use within a crack closure system. The extrusion and die-drawing procedure used to manufacture a series of PET tendon samples is described. The results from a set of restrained shrinkage tests, undertaken at differing activation temperatures, are also presented along with the mechanical properties of the most promising samples. The stress developed within the tendons is found to be related to the activation temperature, the cross-sectional area and to the draw rate used during manufacture. Comparisons with commercially-available PET strip samples used in previous research are made, demonstrating an increase in restrained shrinkage stress by a factor of two for manufactured PET filament samples. / Thanks must go to the EPSRC for their funding of the Materials for Life (M4L) project (EP/K026631/1) and to Costain Group PLC. for their industrial sponsorship of the project and author.

In this study the plane linear elastic problem of a functionally graded layer which contains periodic cracks is considered. The main objective of this study is to determine the thermal stress intensity factors for edge cracks. In order to find an analytic solution, Young&rsquo / s modulus and thermal conductivity are assumed to be varying exponentially across the thickness, whereas Poisson ratio and thermal diffusivity are taken as constant. First, one dimensional transient and steady state conduction problems are solved (heat flux being across the thickness) to determine the temperature distribution and the thermal stresses in a crack free layer. Then, the thermal stress distributions at the locations of the cracks are applied as crack surface tractions in the elasticity problem to find the stress intensity factors. By defining an appropriate auxiliary variable, elasticity problem is reduced to a singular integral equation, which is solved numerically. The influence of such parameters as the grading, crack length and crack period on the stress intensity factors is investigated.

Master of Science / Industrial & Manufacturing Systems Engineering / Shuting Lei / Transparent brittle materials such as glass and silicon dioxide have begun to replace the conventional materials due to the advantageous properties including high strength and hardness, resistance to corrosion, wear, chemicals and heat, high electrical isolation, low optical absorption, large optical transmission range and biocompatibility. However because these materials are extremely hard and brittle, development of an ideal machining process has been a challenge for researchers. Non-traditional machining processes such as abrasive jet and ultrasonic machining have improved machining quality but these processes typically results with issues of poor surface integrity, high tool wear and low productivity. Therefore a machining technique that overcomes the disadvantages of existing methods must be developed. This study focused primarily on improving the machinability and attaining crack-free machined surfaces on transparent brittle materials by inducing micro cracks or seed damages on the subsurface of the materials. The hypothesis was that micro-cracks induced by femtosecond laser would synergistically assist the material removal process by a cutting tool by weakening or softening the material, followed by conventional machining process. Laser induced damages due to varying laser intensities and at different depths in bulk BK7 glass was studied in order to select the optimal laser machining conditions for the experiments. Dimensional and structural profiles of laser cracks are observed using an optical microscope. A comparative study of machined untreated BK7 samples and damage induced BK7 samples was conducted. Due to its simple process kinematics and tool geometry, orthogonal machining is used for the study. Results showed that machining laser-treated samples caused an average 75% force reduction on comparison to machining of untreated samples. Laser treated machined samples were produced without subsurface damages, and reduced tool wear was noted. Overall improved machinability of BK7 glass samples was achieved.

In dieser Arbeit wird die Strukturbildung beim Risswachstum im stationären und instationärem Temperaturfeld im Rahmen der linear-elastischen Bruchmechanik analysiert und numerisch mittels der Methode der finiten Elemente (FEM) untersucht. Die beim langsamen Eintauchen eines heißen schmalen Glasstreifens in kaltes Wasser mit wachsender Temperaturdifferenz oder Eintauchgeschwindigkeit beobachteten Übergänge zwischen keinem, einem geraden und einem oszillierenden Riss werden in ein morphologisches Diagramm eingetragen und die Art des Überganges zur oszillierenden Rissausbreitung bestimmt. Die theoretischen Ergebnisse werden mit Experimenten verschiedener Autoren verglichen. Gleichartige Untersuchungen werden für die Ausbreitung mehrerer Risse durchgeführt. Beim Abschrecken einer erwärmten breiten Probe entstehen hierarchisch geordnete Risslängenstrukturen. Das Skalenverhalten der Rissdichte in Abhängigkeit von der Risslänge wird untersucht. Die Theorie liefert ohne Fitparameter eine sehr gute Übereinstimmung mit dem Experiment. / This paper investigates the formation of crack patterns in stationary and transient temperature fields analytically with linear elastic fracture mechanics and numerically with the finite elements method (FEM). In particular, we consider the experimental situation of a narrow thin strip of hot glass slowly lowered into cold water, with temperature difference and velocity as variable parameters. The parameter regions of no crack, one straight crack and one oscillating crack are determined. The type of phase transition related to the borderline between straight and oscillating crack is characterized. The theoretical results are compared with those of other authors. Similar investigations and comparisions are done for the propagation of multiple cracks. Quenching of a wide thin strip leads to a hierarchy of cracks whose scaling properties are analyzed. Without any fitting, theory and experiment agree surprisingly well.

In dieser Arbeit wird die Strukturbildung beim Risswachstum im stationären und instationärem Temperaturfeld im Rahmen der linear-elastischen Bruchmechanik analysiert und numerisch mittels der Methode der finiten Elemente (FEM) untersucht. Die beim langsamen Eintauchen eines heißen schmalen Glasstreifens in kaltes Wasser mit wachsender Temperaturdifferenz oder Eintauchgeschwindigkeit beobachteten Übergänge zwischen keinem, einem geraden und einem oszillierenden Riss werden in ein morphologisches Diagramm eingetragen und die Art des Überganges zur oszillierenden Rissausbreitung bestimmt. Die theoretischen Ergebnisse werden mit Experimenten verschiedener Autoren verglichen. Gleichartige Untersuchungen werden für die Ausbreitung mehrerer Risse durchgeführt. Beim Abschrecken einer erwärmten breiten Probe entstehen hierarchisch geordnete Risslängenstrukturen. Das Skalenverhalten der Rissdichte in Abhängigkeit von der Risslänge wird untersucht. Die Theorie liefert ohne Fitparameter eine sehr gute Übereinstimmung mit dem Experiment. / This paper investigates the formation of crack patterns in stationary and transient temperature fields analytically with linear elastic fracture mechanics and numerically with the finite elements method (FEM). In particular, we consider the experimental situation of a narrow thin strip of hot glass slowly lowered into cold water, with temperature difference and velocity as variable parameters. The parameter regions of no crack, one straight crack and one oscillating crack are determined. The type of phase transition related to the borderline between straight and oscillating crack is characterized. The theoretical results are compared with those of other authors. Similar investigations and comparisions are done for the propagation of multiple cracks. Quenching of a wide thin strip leads to a hierarchy of cracks whose scaling properties are analyzed. Without any fitting, theory and experiment agree surprisingly well.

Functionally graded materials (FGMs) are composites with continuous material property variations. The distinct interfaces between the reinforcement and the matrix in classical composites are potential damage initiation sites. The concept of FGM aims at avoiding the material mismatch at the interfaces. Functionally graded materials originated from the need for a material that has high-toughness at very high operating temperatures that occur in rocket nozzles and aeroplane engines. One of the early applications of graded materials can be thus found in thermal barrier coatings of gas turbine blades. Recent applications of FGMs include optoelectronics, ballistic impact resistance structures, wear resistant coatings and others. Although the manufacturing and applications of FGMs are well developed the basic mechanics of failure is not well understood, which is important in developing engineering design methodologies. Modern day design practice uses the concepts of fracture mechanics and the fracture properties of graded materials is not well understood. Most studies in the literature have assumed that the material response of the bulk functionally graded material to be elastic even though the constituents are nominally ductile. Some asymptotic analysis available in the literature have described the effect of ductility on the fracture parameters. However, these analysis are not complete in the sense that they have some undetermined constants. The present thesis aims at performing whole-field finite element (FE) simulations of a crack embedded in a ductile functionally graded material subjected to an anti-plane shear (mode-3) loading. A J2-deformation theory based power-law hardening nonlinear material response is assumed. The material property variation is assumed to be in the radial-direction (r-FGM), tangential to the crack (x-FGM), normal to the crack plane (y-FGM) and also at an arbitrary angle to the crack-plane (xy-FGM). Yet another power law described the material property variation. The competition between the indices of the hardening and material property variation is understood by performing a parametric analysis by varying both systematically. Our results indicate that the first most singular term of the asymptotic series remains unaffected. For some values of the material property variation index, the second asymptotic term is affected. The semi-closed form solutions available in the literature were unable to decipher the relative range of dominance of the first and second terms. From the present whole-field FEM analysis were able to extract this relative range of dominance. Our results indicate the range of dominance of the first term is least for FGMs when the material property variation is in the direction to the crack (x-FGM), and it is more for y-FGM.

Malgré les innovations technologiques, les éoliennes restent sujettes à des défaillances prématurées de composants mécaniques imposants, ayant des conséquences considérables sur le coût de l’énergie. Parmi les défaillances majeures au sein des roulements d’éoliennes, un mode de fatigue de contact atypique se caractérise par de vastes réseaux de fissures ramifiées avec des phases microstructurales adjacentes d’apparence blanche à l’origine de la dénomination White Etching Cracks (WEC). Contrairement à la fatigue de contact classique, les WEC apparaissent pour un nombre de cycles et des charges relativement faibles, menant à une défaillance du composant imprévisible selon les modèles de durée de vie actuels. Les WEC ont été observés chez tous les roulementiers, dans diverses applications industrielles et pour différents types de roulements, éléments, lubrifiants, aciers et traitements thermiques. Ce manque de dénominateur commun rend les WEC difficilement reproductibles sur bancs d’essai sans chargement artificiel en hydrogène de l’acier. Ainsi, pour le moment, la formation des WEC ne fait pas l’objet d’un consensus. Une analyse des reproductions de WEC a été menée afin d’en comprendre les mécanismes tribologiques. Des protocoles expérimentaux ont été établis pour révéler les WEC, souvent situés à des positions inhabituelles par rapport au contact. Leur reproduction sur des roulements standards, chargés ou non en hydrogène, a permis de démontrer que le chargement artificiel en hydrogène, jusque-là couramment employé pour étudier la défaillance, reproduit des faciès identiques mais semble modifier l’initiation des WEC. Ainsi, des reproductions de WEC sans chargement en hydrogène et dans des configurations différentes ont été comparées afin d’appréhender les phénomènes tribologiques à l’origine des WEC. Les résultats suggèrent que l’initiation est principalement déclenchée par des phénomènes de surfaces avec l’absorption tribochimique d’hydrogène au niveau des surfaces métalliques fraîches sur la piste de roulement ou au niveau des flancs de microfissures superficielles. La propagation est ensuite assistée chimiquement par l’hydrogène concentré en pointe de fissure. Un arbre des causes étendu révèle que les WEC peuvent être associées à de multiples combinaisons de conditions opératoires qui semblent cependant conduire à des paramètres tribologiques similaires à l’échelle du contact avec, notamment, des cinématiques de glissement, des formulations de lubrifiants spécifiques et des paramètres tribochimiques catalyseurs comme la présence d’eau et/ou d’électricité. Une vaste campagne d’essai a alors été conduite sur un tribomètre bi-disques afin de simuler la fatigue de contact. Les résultats confirment que les facteurs influents identifiés ne sont pas pour autant auto-suffisants. La formation des WEC repose sur un équilibre instable entre aspects matériaux, mécaniques et tribochimiques, à maîtriser pour concevoir des solutions industrielles. / Despite constant expansion and engineering progress, wind turbines still present unexpected failures of heavy duty mechanical components drastically affecting the cost of energy. Among the most prevalent tribological failures in wind turbine rolling element bearings, a peculiar rolling contact fatigue mode has been associated to broad subsurface three-dimensional branching crack networks bordered by white etching microstructure, and thus named White Etching Cracks (WEC). Compared to conventional microstructural alterations, WECs tend to develop at moderate loads and cycles eventually leading to premature failures that remain unpredictable using fatigue life estimations. Far from being generic to specific manufacturers, WECs occur in various industrial applications, for various bearing types, components, lubricants, steels grades and heat treatments. As WEC occurrences present no common evident denominator, they remain delicate to reproduce on laboratory test rigs without prior artificial hydrogen charging, so that no consensus on WEC formation mechanisms have been confirmed yet. In this study, a thorough tribological analysis of WEC formation mechanisms has been led. Expertise protocols have been established to best reveal and observe WECs that commonly develop at unconventional locations versus the contact area. First analysis of WEC reproductions on standard rolling element bearings either hydrogen precharged or kept neutral have signified that artificial hydrogen charging, commonly employed to apprehend the failure mode, results in similar WEC morphologies but tends to alter WEC tribological initiation. In consequence, WEC reproductions in remarkably different configurations but without hydrogen charging have been compared in order to propose a better understanding of WEC surface-affected formation mechanisms: first, initiation via tribochemical hydrogen permeation at nascent steel surfaces formed either directly at the raceway or at surface microcracks flanks and second, propagation by local hydrogen embrittlement at crack tips function of the stress state. An extensive root cause analysis have then been led suggesting that WEC may be associated to various combinations of macroscopic operating conditions that often interact and come down to similar tribological parameters including high sliding energy thresholds, specific lubricant formulations and tribochemical drivers such as water contamination and/or electrical potentials. Further investigations on a minimalist twin-disc fatigue tribometer have provided additional evidence that WEC influent drivers are non-self-sufficient, supporting that WEC formation mechanisms rely on a subtle equilibrium between tribo-material, tribo-mechanical and tribo-chemical drivers that all should be mastered to design efficient and durable countermeasures.

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The diploma thesis is dealing with the topic of new trends in asphalt road routine maintenance with a focus on new possibilities to repair damaged road surface, especially potholes and cracks. In the diploma thesis, a new advice which uses microwave heating in resurfacing asphalt roads was developed with the aim to observe its effectiveness and the optimal repair time. The obtained results were consulted with the producer of the equipment in order to utilize this new technology for repairing potholes and cracks on asphalt road surface in standard practice.