The performance of paperboard materials in packaging application has been investigated and evaluated for a long time. This is because it plays a decisive role for product protection and decoration in packaging applications. Potential damages during transportation sometimes affect the consistency of the performance. Therefore, the capability of the material to resist these external disturbances was of interest. A multiply paperboard was chosen as the experimental material. The analysis conducted in this thesis aimed to reveal the tensile behavior in the cross-machine direction (CD) of the material against various kinds of local or global changes. The changes included global and local climate variations, cutouts, and regional weakening and strengthening, which were applied during the intervals between preloading and reloading. The digital image correlation (DIC) analysis computed the time-varying strain fields from the gray level information contained in the recorded videos of loading processes.  The generated strain fields were imported to post analysis. Comparison between comparable stages (two stages with the same average strain value from different loading sections) was considered as the scheme of isolating the influences of the changes and investigating them individually. The cosine image similarity method and the eigenface algorithm were used to validate this scheme, while the directional average calculation and the strain field compensation method were introduced to realize the isolation. The differences between the front and back outer plies of the paperboard sheets were detected as individual. Moreover, both global and local climate changes were affecting the strain distributions of the specimens proportionally on account of the moisture ratio within the material. In addition, the invisible mechanical weakening and strengthening were captured evidently with the analysis, which caused strain concentrations due to the uneven distribution of expansion capability. The relaxation and bending in unloading processes were two of the primary disturbing factors within all the deformed specimens, which were related to time and bending direction, correspondingly. / Egenskaperna hos kartongmaterial för förpackningstillämpningar har varit ett ämne att undersökning under lång tid. Detta för att dessa egenskaper spelar en avgörande roll som produktskydd och dekorativ utformning i mängde av tillämpningar. Potentiella skador under transport påverkar bland annat materialets tillförlitlighet och prestandard. Därför är det aktuellt att undersöka samt förstå materialets förmåga att motstå yttre störningar. Experimentmaterialet som användes bestod av en typ av flerskiktskartong. Analyser som utfördes i denna avhandling har syfte att identifiera de mekaniska förändringarna i materialets dragegenskaper i tvärsmaskin-riktningen (CD) på grund av olika lokala eller globala förändringar. Förändringarna innefattar både globala och lokala klimatvariationer, utskärningar, och lokala försvagningar samt förstärkningar. Dessa förändringar infördes vid intervallet mellan på- och avlastning. Den digital bildkorrelations analys (DIC) användes för att beräknade de tidsvarierande töjningsfälten från den grånivåinformationen i som registrerades med hjälp av inspelade videor under belastningen  Den genererade töjningsfälten importerades för vidare analys. Två tillstånd med liknande medelvärde av töjningsnivån från olika delar av belastningen jämfördes, detta för att isolera påverkan av förändringarna och undersöka dem individuellt. Två olika metoder för jämförelse av bilderna (cosine image similarity och eigenface algorithm) användes för att validera analysschemat, där riktning-medelvärdesberäkningar och töjningsfälts kompensations-metoden användes för att realisera dessa isoleringar. Enstaka skillnader upptäcktes mellan de främre och bakre ytskikten på kartongarken. Dessutom påverkades töjningsfördelningarna för proverna både av den globala och lokala klimatförändringar på grund av fukttillståndet i materialet. Vidare kan de osynliga mekaniska försvagningar och förstärkningar tydligt fångas med de utförda analyserna, vilket ledde till töjningskoncentrationers uppkomst på grund av det inhomogena expansions-förmåga hos arket. Relaxationen och böjningen vid avlastning relaterade till tid och böjningsförmåga var två av de primära faktorerna som påverkade analysens kvalité.

In this study, we quantified the Chemistry-Process-Structure-Property (CPSP) relations of a Ti-6Al-4V/TiB functionally graded material to assess its ability to withstand large deformations in a high throughput manner. The functionally graded Ti-6Al-4V/TiB alloy was created by using a Laser Engineered Net Shaping (LENS) process. A complex thermal history arose during the LENS process and thus induced a multiscale hierarchy of structures that in turn affected the mechanical properties. Here, we quantified the functionally graded chemical composition; functionally graded TiB particle size, number density, nearest neighbor distance, and particle fraction; grain size gradient; porosity gradient. In concert with these multiscale structures, we quantified the associated functionally graded elastic moduli and overall stress-strain behavior of eight materials with differing amounts of titanium, vanadium, aluminum, and boron with just one experiment under compression using digital image correlation techniques. We then corroborated our experimental stress behavior with independent hardening experiments. This paper joins not only the Process-Structure-Property (PSP) relations, but couples the different chemistries in an efficient manner to effectively create the CPSP relationships for analyzing titanium, aluminum, vanadium, and boron together. Since this methodology admits the CPSP coupling, the development of new alloys can be solved by using an inverse method. Finally, this experimental data now lays down the gauntlet for modeling the sequential CPSP relationships.

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Digital image correlation is a contactless optical method used for displacement and strain measurement which has become increasingly popular in the field of experimental mechanics. A specialized use case for the algorithm is to measure the clamping force in bolted joints, a crucial metric when considering the longevity and reliability of the constructs. However, in order to be able to measure the clamping force in real-time, the digital image correlation has to be carried out rapidly as the tightening of the bolts can happen in milliseconds. One approach to increase the speed of the process is hardware acceleration. This thesis presents and evaluates multiple variations of an Field Programmable Gate Arrays (FPGA)-accelerated digital image correlation framework. The goal of the project is to accelerate the image correlation to sufficient speeds so it can be used for highly dynamic and continuous tightenings, which can take 20 to 200 ms and 200 to 1000 ms or more to finish respectively. A baseline implementation was created based on an innovative digital image correlation framework. Strain calculation was altered for the specialized use of clamping force determination. Afterward, different parts of the framework were selected and optimized for hardware acceleration. The parts include both preprocessing and correlation steps. The targets for acceleration were optimized using techniques such as quantization and pipelining. The accelerators were created using high-level synthesis and the resulting implementations utilize both the processor and FPGA parts of a Zynq-7000 system-on-chip. Results show that all accelerators reduce the total execution time of the framework by varying degrees. Accelerators targeting the preprocessing parts such as Gaussian and B-spline filtering proved to be the most effective in speeding up the process achieving a 1,56 and 1,12 times speedup for the fixed-point and a 1,2 and 1,07 times speedup for the double floating-point versions respectively. A combined version containing multiple accelerators resulted in a 1,9 times average speedup. It can be concluded that the presented approach is not fast enough for all highly dynamic tightening processes, as the fastest execution speed achieved is above 100 ms, but could be used for continuous tightening depending on constructs. / Digital image correlation(DIC) är en kontaktlös optisk metod, använd för mätning av förskjutning och töjning, som blivit en allt mer populär inom experimentell mekanik. Ett användningsområde för algoritmen är att mäta klämkraften i skruvförband, en avgörande faktor för hållbarhet och tillförlitlighet i konstruktioner. Men för att mäta klämkraft i realtid, behöver DIC utföras väldigt snabbt då åtdragningsförloppet kan ske inom loppet av millisekunder. En metod för att öka hastigheten är hårdvaruacceleration. Denna avhandling presenterar och utvärderar ett flertal varianter av ett Field Programmable Gate Arrays (FPGA)-accelererat DIC ramverk. Avhandlingen syftar till att accelerera bildkorrelationen tillräckligt mycket för att kunna användas till dynamiska och kontinuerliga åtdragningar som tar 20 till 200 ms respektive 200 till 1000 ms eller mer. En referens-implementation skapades baserat på ett innovativt DIC ramverk. Beräkning av töjning anpassades för specialfallet: bestämmandet av klämkraft. Efter det valdes olika delar av ramverket ut och optimerades för hårdvaruacceleration. De valda delarna innehåller både preprocessor- och korrelationssteg. Delarna som valdes ut för acceleration optimerades med hjälp av tekniker som kvantisering och pipelining. Acceleratorerna skapades med hjälp av high-level synthesis och de resulterande implementationerna använder både processor och FPGA i en Zynq-7000 system-on-chip. Resultaten visar att alla acceleratorer reducerar ramverkets totala exekveringstid med varierande grad. Acceleratorer som riktar sig mot preprocessing som Gaussian och B-spline filtrering visade sig vara mest effektiva och resulterade i en 1.56 respektive 1.12 gånger snabbare exekveringstid för fixed point, och 1.2 respektive 1.07 gånger snabbare exikveringstid för double floating-point. En kombinerad version som innehöll flera acceleratorer resulterade i en 1.9 gånger snabbare genomsnittlig exekveringstid. Slutsatsen är att den presenterade metoden inte är tillräckligt snabb för alla dynamiska åtdragningsförlopp, då den snabbaste uppnådda exekveringstiden är över 100 ms. Men metoden skulle kunna användas för kontinuerliga åtdragningar beroende på konstruktionen.

Formable Advanced High-Strength Steels (AHSS) have a unique combination of strength and ductility, making them ideal in the effort to lightweight vehicles. The AHSS in this study, Quenched and Partitioned 1180, rely on the Transformation Induced Plasticity (TRIP) effect, in which retained austenite (RA) grains transform to martensite during plastic deformation, providing extra ductility via the transformation event. Understanding the factors involved in RA transformation, such as local strain and grain attributes, is therefore key to optimizing the microstructure of these steels. This research seeks to increase understanding of those attributes and the correlations between microstructure and RA transformation in TRIP steels. To measure local strain, the viability of using forescatter detector (FSD) images as the basis for DIC study is investigated. Standard FSD techniques, along with an integrated EBSD / FSD approach (Pattern Region of Interest Analysis System), are both analyzed. Simultaneous strain and microstructure maps are obtained for tensile deformation up to around 6% strain. The method does not give sub-grain resolution, and surface feature evolution prevents DIC analysis across large strain steps; however, the data is easy to obtain and provides a natural set of complementary information for the EBSD analysis. In-situ tensile tests combined with EBSD allow RA grain and neighboring attributes to be characterized and corresponding transformation data to be obtained. However, pseudo-symmetry of the ferrite (BCC) and martensite (BCT) phases prevents EBSD from accurately identifying all phases. Measuring the relative distortion of the crystal lattice, tetragonality, is one approach to identifying the phases. Unfortunately, small errors in the pattern center can cause significant errors in tetragonality measurement. Therefore, this research utilizes a new approach for accurate pattern center determination using a strain minimization routine and applies it to tetragonality maps for phase identification. Tetragonality maps based on dynamically simulated patterns result in the most accurate maps and can also be used to predict approximate local carbon content. Machine learning is then used on the collected data to isolate key attributes of RA grains and provide a decision tree model to predict transformation based on those attributes. Among the most relevant attributes found, RA grain area, RA grain shape aspect ratio, a “hardness” factor, and major axis orientation are included. Possible correlations between these factors and transformation improve understanding of relevant attributes and show the advantage that machine learning can have in unravelling complex material behavior.

As technology is developing in all automotive companies, car body designers have also investigated new materials such as composite and aluminum alloys. Designing modern car structures has also created various challenges in the production process, including formability limitations. The main purpose of this research work was to develop a test setup for an open-hole uniaxial tensile test and investigate the effect of the cutting tool on the shearing edge quality of the series 6000 aluminum alloy and materials formability as a result. To approach this significant issue, detecting the onset of necking and forming limit curves FLC using 3D digital image correlations (DIC) capabilities were studied. Two methods based on strain rate for evaluating the instability through 3D DIC and Matlab were applied. Eighteen specimens in rolling, transverse, and diagonal directions were investigated. Although the results of the tensile test machine are close for all tests, due to 3D DIC limitations, detecting the onset of necking was hard to obtain.

Bending deformation characteristics of monolithic, bi-layer and tri-layer laminate sheet materials are studied using Analytical and FE models in this work. The analytical model, based on advanced theory of pure bending considers von Mises yielding, Ludwik hardening law and Bauschinger effect for various laminate constituent thickness ratios. The principal stresses and strains through the thickness and, change in relative thickness at specified bend curvatures are obtained as a function of increasing curvature during bending. Additionally, 2D and 3D finite element (FE) based models for bending are developed to overcome simplifications of the analytical models such as the effect of specimen width on strain distribution. Further, to experimentally assess and validate bending characteristics from the analytical models, a new experimental bend test-jig that is closer to pure bending is developed. The experimental set-up is an open concept design that allows access to the tensile surface as well as through-thickness region for recording and analyzing strains using an online strain mapping system based on digital image correction (DIC) method. Experimental bending is carried out on annealed AA2024 monolithic aluminum alloy sheet and Steel/Aluminum (SS400/AA1050) bi-layer laminate sheet at different thickness ratios. The model and experiments are studied in terms of stress and strain distribution as a function of relative thickness for different clad to matrix thickness ratios. Further the case of simultaneous bending and stretching over small radius bending is analyzed for limit strain prediction using an existing limit strain criterion based on major strain acceleration. An angular stretch bend test is used to subject an hour-glass shaped AA20240-O aluminum sheet specimen to simultaneous stretching and bending deformation while continuously imaging the critical tensile surface region using an optical camera. The strain development in the critical region is subsequently analyzed using digital image correlation (DIC) method. The effect of DIC parameters such as facet size, facet step, and effect of curve fitting procedures on limit strain are studied. An average limit strain of 0.2 is obtained for AA2024 for a facet size of 9x9 pixels, a facet step of 5 pixels and by applying a 5th order polynomial curve fit to the strain data. The results obtained are comparable with a limit strain of the material. The results are compared with a commercially available tri-layer laminate sheet material Alclad 2024 that has 80 μm thin layer of soft AA1100 on both surfaces of harder AA2024 core material. An improved stretch bendability limit strain of 0.24 for Alclad 2024 tri-layer specimen was predicted by utilizing the major strain acceleration criterion. The thin AA1100 protective layer produced a positive effect on the stretch bendability of Alclad 2024 when compared with monolithic AA2024 specimen. / Thesis / Doctor of Philosophy (PhD)

For reducing the CO2 footprint in many industrial fields, the goal is to produce lighter components. The aluminium-silicon (Al-Si) cast alloys are promising candidates to fulfill these goals with a high weight-to-strength ratio, good corrosion properties, excellent castability, and recyclable material. However, the variations within these components need to be understood to produce high-performance components for critical applications. The main reason for the rejection in these applications is defects and microstructural features that reduce the mechanical properties. The addition of copper (Cu) is one way of increasing the mechanical properties in Al-Si alloys and is commonly used in the automotive industry. Casting defects harm the mechanical properties, and these defects can be reduced by improving the melt quality, the correct design of the component, and the gating system. The study aims to investigate the static mechanical properties and the crack initiation and propagation under cyclic loading in an Al-7Si-Mg cast alloy with state-of-the-art experiments. The main focuses were on the effect of the HIP process and the role of Cu addition. In-situ cyclic testing using a scanning electron microscope coupled with electron back-scattered diffraction, digital image correlation, focused ion beam (FIB) slicing, and computed tomography scanning was used to evaluate the complex interaction between the crack path and the microstructural features. The amount of Cu retained in the α-Al matrix in as-cast and heat-treated conditions significantly influenced the static mechanical properties by increasing yield strength and ultimate tensile strength with a decrease in elongation. The three-nearest-neighbor distance of eutectic Si and Cu-rich particles and crack tortuosity were new tools to describe the crack propagation in the alloys, showing that a reduced distance between the Cu-rich phases is detrimental for the mechanical properties. Three dimensional tomography using a FIB revealed that the alloy with 3.2 wt.% Cu had a significantly increased quantity of cracked Si particles and intermetallic phases ahead of the crack tip than the Cu-free alloy. The effect of Cu and HIP process in this work shows the complex interaction between the microstructural features and the mechanical properties, and this needs to be considered to produce high-performance components. / Ett sätt att nå målen med minskade koldioxidutsläpp inom industrin är att producera lättare komponenter. Aluminium-kisel (Al-Si) gjutna legeringar är därför ett bra alternativ då dessa legeringar har ett bra förhållande mellan hållfasthet och vikt, goda korrosionsegenskaper, utmärkt gjutbarhet och är ett återvinningsbart material. En av de största utmaningarna för att producera högpresterande komponenter för kritiska applikationer är variationerna i egenskaper inom dessa komponenter. Orsaken till att inte gjutna Al-Si legeringar andvänds i dessa applikationer är förståelsen av defekter och mikrostruktuella faser påverkar de mekaniska egenskaperna negativt. Koppar (Cu) tillsätts i Al-Si legeringar för att öka de mekaniska egenskaperna vilket ofta nyttjas inom bilindustrin. Hot isostatic pressing (HIP) prosessen är en annan möjlighet att förbättra de mekaniska egenskaperna genom att reducera porositeter i materialet. Studien syftar till att undersöka de mekaniska egenskaperna och sprickinitiering och spricktillväxt i en gjuten legering av Al-7Si-Mg med utmattningstestning i svepelektronmikroskop (SEM) i kombination med electron backscatter diffraction, digital image correlation och focused ion beam (FIB). Mängden Cu i Al-Si legeringen påverkade de statiska mekaniska egenskaperna genom att öka sträckgränsen och brottgränsen. Tillsats av Cu upp till 1.5 vikt.% påverkar inte spricktillväxten märkbart. Däremot förändras beteendet markant vid tillsatser av Cu på mer än 3.0 vikt.% som resulterade i en markant reducering i duktilitet. I det värmebehandlade materialet påverkades de mekaniska egenskaperna av Al-matrisen och mängden intermetalliska faser. Avståndet mellan Cu faserna och Si faserna används för att beskriva spricktillväxten i Al-Si legeringarna. Detta tillsammans med tredimensionell tomografi visade att legeringen med 3.2 vikt.% Cu hade en ökad mängd sprickor i området framför den avancerande sprickan, vilket inte den Cu fria legeringen visade. Al-Si legeringen som utsattes för HIP-processen och värmebehandlingen visade att materialets mikrostruktur i gjutet tillstånd påverkade resultatet. HIP processen slöt porositerena i alla undersökta prover och förbättrade de mekaniska egenskaperna. Dessa resultat kommer kunna användas för att konstruera mer högpresterande komponenter.

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