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Wear and corrosion are two major threats to material integrity in multiple real-life circumstances, including oil and gas pipelines, marine and offshore infrastructures and transportations and biomedical implants. Furthermore, the synergistic effects between the two, named tribocorrosion, could cause, most of the time, severer material degradation to jeopardize materials' long-term sustainability and structural integrity. A representative case is aluminum (Al) and its alloys, which exhibit good corrosion resistance in aqueous solution due to the protection provided by the passive layer. However, these naturally formed layers are thin and delicate, leaving the materials vulnerable to simultaneous mechanical and corrosion damage, which in turn, compromise their resistance to tribocorrosion. Past research in tribocorrosion mainly relies on costly and trial-and-error experimental methods to study the materials' deformation and degradation under simultaneous wear and corrosion. In an attempt to predict tribocorrosion behavior using numerical analysis, this work developed a set of finite-element-based multiphysics models, in combination with experimental methods for parameter input and validation, focusing on different factors influencing the tribocorrosion behavior of materials. The first study developed a model with the coupling between strain and corrosion potential and investigated the effect of bulk material properties on tribocorrosion. This model was validated by existing tribocorrosion experiments of two Al-Mn alloys, to analyze the synergistic effects of mechanical and corrosion properties on the material degradation mechanisms of tribocorrosion. During consecutive passes of the counter body, significant residual stress was found to develop near the edge of the wear track, leading to highly concentrated corrosion current than elsewhere. Such non-uniform surface corrosion and stress-corrosion coupling led to variations of tribocorrosion rate over time, even though testing conditions were kept constant. Tribocorrosion rate maps were generated to predict material loss as a function of different mechanical and electrochemical properties, indicating a hard, complaint metal with high anodic Tafel slope and low exchange current density is most resistant to tribocorrosion. Secondly, the influence of microstructural design on the tribocorrosion behavior of Al-based nanostructured metallic multilayers (NMMs) was investigated computationally. Specifically, this model accounts for elastic-plastic mechanical deformation during wear and galvanic corrosion between exposed inner layers after wear. The effects of individual layer thickness (from 10 to 100 nm) and layer orientation (horizontally and vertically aligned) on the tribocorrosion behavior of Al/Cu NMMs was studied. Both factors were found to affect the subsurface stress and plastic strain distribution and localized surface corrosion kinetics, hence affecting the overall tribocorrosion rate. This model and the obtained understanding could shed light on future design and optimization strategies of NMMs against tribocorrosion. Finally, a combined experimental and computational investigation of the crystallographic effect using Al (100), (110), and (111) single crystals as model systems, to understand the effects of crystallographic orientation on the tribocorrosion kinetics by combining tribocorrosion experiments, materials characterization, and multiphysics modeling. EBSD was exploited to characterize the crystal orientation and dislocation density of the worn samples. The tribocorrosion model was built based on the results of EBSD characterization with the coupling effect of crystal orientation and corrosion. The model successfully predicted the overall tribocorrosion current of single-crystal samples, indicating the important role played by crystal orientation and dislocation density in the acceleration of corrosion. / Doctor of Philosophy / Multiple applications in batteries, aerospace, marine transportation, offshore infrastructure and biomedical implants request metal materials that are both mechanically reliable and corrosion resistant. In addition to pure mechanical wear and corrosion, the synergy of the two, which is called tribocorrosion, also poses major threat to materials' integrity and longevity. Aluminum is a widely used passive metal due to its advantage of being cheap, light-weighted and corrosion resistant, but is relatively less resistant to wear comparing to other metals. Mechanical damage could strip Al of the protection from the passive layer and also cause stress corrosion. This makes Al susceptible to tribocorrosion. Despite several previous experimental attempts to understand the mechanism of Al tribocorrosion and improve the tribocorrosion resistance of Al by alloying or structural design, there has been little quantitative model on this topic. In this dissertation, finite element (FE) multi-physics modeling was exploited to investigate the tribocorrosion phenomenon on Al systems in sea water environment. The first model was developed based on strain-electrochemistry coupling and helped study the effect of alloys' composition on the tribocorrosion resistance of the alloy. The second model studied the tribocorrosion of Al/Cu multilayers with the focus on the micro-galvanic coupling between Al and Cu layers and predicted the influence of layer thickness and orientation. The third model exploited the result of crystallographic information from EBSD characterization to study the mechanism of pure Al tribocorrosion on the crystal level. These models provide quantitative explanation to the accelerated corrosion of Al-based metals and structures, as well as guidance to future design of material with optimum wear, corrosion and tribocorrosion resistance.

Human activities associated with the injection of fluids at depth are known to trigger earthquakes. Fluid injection increases the internal pore pressure of the host rock, which in turn reduces the effective stress and frictional resistance of faults that maintain the fractured rock system in a state of mechanical equilibrium. Under certain conditions, sufficiently high pore pressure can lower this frictional resistance below a critical threshold and initiate an earthquake – the relative motion of rock on either side of the fault plane. Many of these earthquakes are small and imperceptible without the aid of specialized instruments, but some may be large enough to pose a significant risk to life and property. Several emerging technologies that have the potential to shape the future of low-carbon energy production, including carbon capture and storage and enhanced geothermal energy production, are inextricably linked to large-scale injection of fluids into the subsurface. The risk of injection-induced earthquakes is a primary concern and potential barrier to widespread adoption of these technologies. New tools are required to help operators manage these risks and meet stakeholder expectations. Current knowledge enables operators to predict the conditions that would trigger such an earthquake, but few or no tools exist to predict the severity of the earthquakes, precluding a complete description of the risk associated with operating a large-scale injection well. This dissertation details the theoretical justification and initial validation of a methodology and software to simulate the motion of an earthquake as it occurs and quantify the severity in terms that are germane to experts in earthquake science. Specifically, this work utilizes the finite element method to solve the equations of motion dictated by the three-dimensional linear elastic constitutive equation. Novel aspects of this research include the treatment of friction at the fault interface as a constraint on the motion of the system, and the numerical methods necessary to solve this problem. This software was created exclusively with free and open source software, so that every aspect of its internal machinery may be scrutinized, replicated, and improved by future workers. / Doctor of Philosophy / Human activities associated with the injection of fluids at depth are known to trigger earthquakes. Many of these earthquakes are small and imperceptible without the aid of specialized instruments, but some may be large enough to pose a significant risk to life and property. Several emerging technologies that have the potential to shape the future of low-carbon energy production, including carbon capture and storage and enhanced geothermal energy production, are inextricably linked to large-scale injection of fluids into the subsurface. The risk of injection-induced earthquakes is a primary concern and potential barrier to widespread adoption of these technologies. New tools are required to help operators manage these risks and meet stakeholder expectations. Current knowledge enables operators to predict the conditions that would trigger such an earthquake, but few or no tools exist to predict the severity of the earthquakes, precluding a complete description of the risk associated with operating a large-scale injection well. This dissertation details the theoretical justification and initial validation of a methodology and software to simulate the motion of an earthquake as it occurs and quantify the severity in terms that are germane to experts in earthquake science. This software was created exclusively with free and open source software, so that every aspect of its internal machinery may be scrutinized, replicated, and improved by future workers.

Many commercial finite element programs support piezoelectric modeling and composite modeling to some extent. The popular program ABAQUS, however, has piezoelectric modeling capabilities only for continuum and one-dimensional truss elements. In situations where aspect ratio constraints and computational inefficiencies become a significant issue, such as modeling very large thin structures, alternate modeling techniques are sometimes required. Much of the focus of this thesis was to introduce equivalent methods for modeling laminated piezoelectric beams and plates. Techniques are derived based on classical beam and plate theory, classical lamination theory, and the linear theory of piezoelectricity. Finite element approximations are used with the principle of minimum potential energy to derive the static equilibrium equations for piezoelectric laminated structures. Equivalent loading techniques are derived based on the constitutive equations of piezoelectricity to simulate actuation forces within the piezoelectric layers. Finite element models using equivalent modeling techniques as well as equivalent loading techniques for piezoelectric laminated structures are developed and compared to ABAQUS models using piezoelectric elements to evaluate the error in theoretical assumptions. The analysis will prove that equivalent structural models and equivalent loading techniques provide excellent means for simplifying the analysis of thin piezoelectric laminated structures. / Master of Science

The Breast Implant Lifetime Study at Virginia Tech, on which this thesis is based, seeks to develop methods and data for predicting the lifetime of saline-filled implants. This research developed Finite Element Analysis (FEA) models to evaluate the stresses that are present in the silicone breast implant material under different loading situations. The FEA work was completed using the commercial codes PATRAN and ABAQUS. PATRAN was used for pre- and post-processing, while ABAQUS was used for the actual analysis and to add fluid and contact elements not supported by PATRAN. Many different loading situations and constraints were applied to these models, as well as variations in the material and model properties. Varying the Poisson's ratio of the implant material from 0.45 to 0.49 did not make a significant difference in the results. Changing the elastic modulus of the implant material from the modulus of a Smooth implant to the modulus of a Siltex implant had a noticeable effect on the stress results, increasing the maximum stresses by almost 8%. Changing the modulus of the surrounding tissue had marked effects as well, with stiffer tissue (E=300 psi) decreasing the implant's stresses by about 60% as compared to softer tissue (E=100 psi). A ten percent decrease in implant thickness yielded a 17% average increase in stress experienced by the implant. For both the 2.5" radius and the 4" radius tissue models, using CAX4 elements produced higher overall stresses in the tissue with the same loading conditions. However, in the 2.5" tissue model, the implant itself experienced less stress with the CAX4 tissue than the CAX3 tissue. In the 4" tissue model, the implant experienced more stress when surrounded by the CAX4 tissue elements. These models will be combined with implant fatigue data to develop a life prediction method for the implant membrane. / Master of Science

This thesis presents a nontraditional treatment for uncertainties in the material, geometry, and load parameters in linear static finite element analysis (FEA) for mechanics problems. Uncertainties are introduced as bounded possible values (intervals). FEA with interval parameters (interval FEA, IFEA) calculates the bounds on the system response based on the ranges of the system parameters. The obtained results should be accurate and efficiently computed. Toward this end, a rigorous interval FEA is developed and implemented. In this study, interval arithmetic is used in the formulation to guarantee an enclosure for the response range. The main difficulty associated with interval computation is the dependence problem, which results in severe overestimation of the system response ranges. Particular attention in the development of the present method is given to control the dependence problem for sharp results. The developed method is based on an Element-By-Element (EBE) technique. By using the EBE technique, the interval parameters can be handled more efficiently to control the dependence problem. The penalty method and Lagrange multiplier method are used to impose the necessary constraints for compatibility and equilibrium. The resulting structure equations are a system of parametric linear interval equations. The standard fixed point iteration is modified, enhanced, and used to solve the interval equations accurately and efficiently. The newly developed dependence control algorithm ensures the convergence of the fixed point iteration even for problems with relatively large uncertainties. Further, special algorithms have been developed to calculate sharp results for stress and element nodal force. The present method is generally applicable to linear static interval FEA, regardless of element type. Numerical examples are presented to demonstrate the capabilities of the developed method. It is illustrated that the present method yields rigorous and accurate results which are guaranteed to enclose the true response ranges in all the problems considered, including those with a large number of interval variables (e.g., more than 250). The scalability of the present method is also illustrated. In addition to its accuracy, rigorousness and scalability, the efficiency of the present method is also significantly superior to conventional methods such as the combinatorial, the sensitivity analysis, and the Monte Carlo sampling method.