In striving to produce high quality cast components from recycled aluminium alloys,imperfections have to be considered, because recycled aluminium usually containsmore of it. However, there are great energy savings to be made by using recycledaluminium; as little as 5% of the energy needed for primary aluminium productionmay be required. High quality castings are dependent on, besides alloy chemistry, bothmelt quality and the casting process; the focus of this work is related to the meltquality.This thesis aims to increase knowledge about imperfections, foremost about Fe-richparticles, oxides/bifilms, and porosity. Experiments were performed at industrialfoundry facilities and in a laboratory environment. Melt quality was evaluated byproducing samples with the reduced pressure test (RPT), from which both densityindex (DI) and bifilm index (BI) could be measured, results that were related to tensiletest properties. Data from tensile test samples were analysed, and fracture surfacesand cross sections were studied in both light microscope and in scanning electronmicroscope (SEM). For the purpose of investigating nucleation of primary Fe-richparticles (sludge) differential scanning calorimetry (DSC) was used.In the analysis of results, a correlation between the morphology of particles and tensileproperties were found. And elongated Fe-rich β-particles were seen to fracturethrough cleavage towards the centre. However, DI and BI have not been possible torelate to tensile properties.The nucleation temperature of primary Fe-rich particles were found to increase withincreased Fe, Mn, and Cr contents, i.e. the sludge factor (SF), regardless of cooling rate.For a set SF, an increase of cooling rate will decrease the nucleation temperature.

When testing forgings for specifications, it was found that some parts did not meet the requirements for mechanical properties. This triggered an investigation into two of the parts from the lot that did not meet specification. The ultimate reason for failure was due to lower than necessary yield strength and ultimate tensile strength values, as well as unwanted variability between regions of the part. Therefore, samples of the regions were tensile tested to determine the differences that existed in yield strength, ultimate tensile strength, and elongation. After tensile testing, quantitative metallography and fractography were conducted to identify aspects of the microstructure and fracture surfaces that may have caused the variability. Three aspects of the microstructure that were identified as characteristics that may affect the mechanical properties were: grain size, Widmanstätten colony size, and volume fraction of the β phase. Based on measurements it was determined that a smaller Widmanstätten colony size found to be roughly 120 microns/colony was associated with a larger yield strength and UTS than larger colony sizes of roughly 170 microns/ colony. Grain size also played a role with smaller grain sizes of roughly 1550 microns/grain being associated with a higher yield strength and UTS than the larger grains of roughly 2000 microns/grain. Fractography also suggested that the presence of interlamellar decohesion and trans-lamellar failure may have created sites of further crack initiation, resulting in a lower ultimate tensile strength. These differences were theorized to be caused by a temperature gradient created during the heat treatment that created non-uniform cooling rates, resulting in the differences in microstructural characteristics.

Thesis (Ph. D.)--Ohio State University, 2009. / Title from first page of PDF file. Includes vita. Includes bibliographical references (p. 380-400).

Les élastomères présentent une diversité d’utilisation et des caractéristiques mécaniques spécifiques (grandes déformations, comportement dissipatif, ...) qui en font une famille de matériaux très utilisés dans l’industrie. Lors de leur fonctionnement, les pièces réelles subissent des sollicitations complexes. Comprendre les phénomènes induits par la fatigue multiaxiale constitue ainsi un enjeu important dans la phase de conception industrielle. Le matériau utilisé au cours de cette étude est un polychloroprène (CR), fourni par la société Hutchinson et présent dans les poulies découpleuses. Celui-ci possède une réponse dissipative en grandes déformations. Son comportement est modélisé à partir de lois de comportements viscohyperélastiques suivant deux approches : une méthode analytique impliquant un calcul simple en un point d’un cylindre et l’autre utilisant un calcul éléments finis implémenté dans ANSYS. Une campagne expérimentale en fatigue multiaxiale est alors réalisée, en traction-torsion afin de tester l’énergie dissipée comme critère de fatigue multiaxial. Celui-ci présente des résultats intéressants. Des diagramme de Haigh ont été établis afin de mettre en évidence le phénomène de cristallisation. Des analyses post-mortem ont été menés avec un microscope électronique à balayage et expose des spécificités morphologiques liées à la sollicitation vue par le matériau. / Due to their interesting mechanical behavior (large strain, dissipative behavior ...) and their diversity, elastomers are more and more used in industry. In service conditions, rubber components are subjected to complex loadings. Therefore, understanding phenomena induced by multiaxial fatigue constitutes an important issue in the industrial conception’s step. The material used in this work is a polychloroprene rubber, provided by Huchinson society and dedicated to silent-block’s applications. This elastomer possess a dissipative component at large strains. This behavior is determined following two approaches : an analytic method, implying a simple calculation at a local point of a cylinder and a finite elements analysis implemented with ANSYS software. An experimental investigation in multiaxial fatigue is then realized to test the dissipated energy density as a multiaxial fatigue criterion. This parameter obtained interesting results. Haigh diagrams has been built to point out crystallization phenomenon. Post-mortem analyses has been carried out with a scanning electronic microscope and exposes morphological specificities related to the material’s sollicitation.

Resumo: Superfícies de fratura expressam a seqüência de eventos de liberação de energia com a propagação de trincas, mostrando a relação entre os componentes da estrutura, campos de tensões locais e a formação de texturas típicas em seu relevo. No caso dos compósitos de matriz polimérica, a evolução das formações topográficas pode indicar as linhas de ação de carga, os efeitos de degradação pelo ambiente ou os defeitos de processamento. Sendo assim, o objetivo deste trabalho é avaliar se as regiões de relevo formadas pelos diferentes mecanismos de propagação de trincas na fratura de compósitos termorrígidos, carbono/epóxi, podem ser relacionadas a diferentes valores de dimensão fractal, correspondendo à sua influência sobre a tenacidade. Os corpos-de-prova de compósito carbono/epóxi foram divididos em três grupos, sendo natural, com condicionamento higrotérmico e com condicionamento ultravioleta. As fraturas analisadas foram provenientes de ensaios DCB, em modo I de carregamento, sendo a aquisição das imagens feitas com o uso de microscópio óptico de reflexão e as topografias das superfícies obtidas pelo método de reconstrução por extensão de foco, calculando-se os valores de dimensão fractal com o uso dos mapas de elevações. A dimensão fractal foi classificada como: dimensão monofractal (Df), quando a fratura é descrita por um único valor; ou dimensão textural (Dt), que é uma análise macroscópica da fratura, combinada com a dimensão estrutural (Ds), que é uma análise microscópica. Os resultados demonstraram que não há relação entre Df e GIC, como proposto por Mecholsky, em seus trabalhos, não sendo esta medida uma propriedade do material. Quanto a Dt, esta medida não pode descrever qualquer propriedade do material, pois se restringe à descrição local do processo de fratura. Já Ds, descreve... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Fracture surfaces express the sequence of events of energy release with crack propagation, showing the relationship between the components of the structure, local stress fields and the formation of textures in his typical relief. In the case of polymer matrix composites, the evolution of topographic features may indicate the lines of action of load, the effects of degradation of the environment or processing defects. Therefore, the objective this work is to assess if the relief regions formed by different mechanisms of crack propagation in the fracture of thermosetting composites, carbon / epoxy, may be related to different values of fractal dimension, corresponding to its influence on toughness. Composite carbon / epoxy specimens were divided into three groups, namely natural, with hygrothermal conditioning and ultraviolet conditioning. The fractures were analyzed from DCB tests in mode I loading, with the acquisition of images by using an optical microscope and the surface topographies obtained by an extended depth-of-field method, calculating the values of fractal dimension with the use of elevation maps. The fractal dimension was classified as: monofractal dimension (Df), when the fracture is described by a single value, or texture dimension (Dt), which is a macroscopic fracture, combined with the structural dimension (Ds), which is a microscopic analysis. The results showed that there isn't relationship between Df and GIC, as proposed by Mecholsky in his work, since this measure is not a material property. As for Dt, this measure cannot describe any property of the material, because it restricts the description of the process to local fracture conditions. In other way, Ds describes the micro-relief and is associated to the forces involved in the rupture of atomic bonds and, thus, to the association between micromechanics and microstructure... (Complete abstract click electronic access below) / Orientador: Luis Rogerio de Oliveira Hein / Coorientador: Edson Cocchieri Botelho / Banca: Marcelo dos Santos Pereira / Banca: Ana Lucia Horovistiz / Mestre

Orientadores: Ana Maria Martinez Nazar e Jean Jacques Ammann / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-07-22T02:22:53Z (GMT). No. of bitstreams: 1 Hein_LuisRogeriodeOliveira_D.pdf: 26678950 bytes, checksum: 210f2815f8a6929d74730d86f2becb68 (MD5) Previous issue date: 1996 / Resumo: O estudo das relações entre a zona de estiramento e a tenacidade à fratura dos materiais para uso em estruturas mecânicas tem encontrado grande interesse no meio científico e tecnológico. Entretanto, grandes restrições vêm sendo encontradas quanto à adoção de técnicas para sua avaliação, o que tem implicado em uma pequena quantidade de trabalhos sobre a geometria dessa região. Desta forma, este trabalho visa o desenvolvimento de um método para análise da superfície da zona de estiramento, baseado nos conceitos das medições de paralaxe e em técnicas de processamento digital de imagens, buscando estabelecer critérios mais precisos para a definição de seus limites naturais e estudar a evolução de sua geometria, através da análise de perfis. O algoritmo para reconstrução tridimensional foi inteiramente desenvolvido dentro do ambiente gráfico do programa KHOROS, criado por pesquisadores da New Mexico University. Empregando-se técnicas de observação em microscópio eletrônico de varredura especialmente adaptadas para este trabalho, foram fotografados pares estereoscópicos de zonas de estiramento formadas em superfícies de fratura de amostras da liga AI 7050, obtidas em ensaios mecânicos para determinação do CTOD crítico, seguindo orientações do método EGF PI-87-D. Assim, foram obtidos perfis de elevação que permitiram realizar medições de parâmetros como a largura e a altura da zona de estiramento, bem como estudar a evolução de sua geometria. A zona de estiramento apresenta relevo muito acidentado, o que provoca uma dispersão natural dos resultados, apesar do emprego de uma definição consistente para a identificação de seus limites. Conclui-se que os perfis da região, desde que sob estado de deformação plana, podem ter sua geometria média descrita pela forma de uma semi-parábola. Esses resultados levaram a concluir que a metodologia e o algoritmo desenvolvidos têm aplicação viável na fractografia quantitativa / Abstract: The study about stretch zone and materiaIs fracture toughness behaviour has been found remarkable interest in the science and technology field. Moreover, there are many restrictions about the use of measurement techniques, noted by a low number of published works related to stretch zone geometry. The goal of this research is to develop a method for stretch zone surface analysis, based on parallax measurement theory using digital image processing techniques, to stablish accurated criteria for its natural boundaries detinition and to study its geometrical evolution, by profilometric analysis. The three-dimensional reconstruction algorithm has been fully developed using the graphic interface of KHOROS program, created by New Mexico University researchers. By means of particular scanning electron microscopy techniques, stretch zone stereo pairs of AI 7050 alloy fracture surfaces were photographed as indicated by EGF Pl-87-D method. These fracture surfaces were obtained from CTOD testing. The reconstructed surfaces were analysed by means of profiles, to measure width and heigth parameters of the stretch zone and to study its geometry. Because the complex stretch zone surface topographies, it was observed a large but natural dispersion of size data, despite the use of a reliable definition for region boundaries identification. So, it is concluded that stretch zone profiles mean geometry, under plane strain, can be described by the semi-parabolic shape. Finally, the results let to conclude that developed methodology and algorithm has viable use for quantitative fractographic analysis / Doutorado / Materiais e Processos de Fabricação / Doutor em Engenharia Mecânica

Made available in DSpace on 2016-03-15T19:36:27Z (GMT). No. of bitstreams: 1 Bruno Ozi Silva Rosalin de Oliveira.pdf: 13422716 bytes, checksum: f7a9b0a01c36feca00f6569994ff6f8d (MD5) Previous issue date: 2011-02-15 / This work has as main objective the determination of mechanical behavior, specially the impact resistance of martensitic structures based on carbon and on alloyed steels. The main concern is the response of these alloys when tempering at low temperatures (below 180°C). Heat treatments were performed by quenching in water and oil in order to determine the severity of the medium through testing the hardness, impact, micrographic and fractographic analysis. The SAE1045 and SAE4140 steels were also subjected to heat treatment tempering at low temperatures, 100°C, 140°C and 180°C, to verify the increase of toughness and possible changes in microstructure of these materials. It was the largest recorded hardenability of SAE4140 steel over SAE1045 steel, in agreement with the literature, through the results of hardness and micrographic analysis performed. The quenching in oil of the SAE4140 steel showed a predominantly martensitic microstructure which generated a hardness greater than SAE1045 steel showed a microstructure of martensite with islands of fine pearlite and ferrite. At all the tempering carried out for SAE1045 stel there is an increase in absorbed energy on impact with increasing temperature, and that these low-temperature tempering have significant influences on the material toughness. The tempering have higher increases of energy absorption and lateral expansion of SAE1045 steel in the conditions of quenching in water than in quenching in oil. For SAE4140 steel quenching in water (not very usual in practice) generated cracks in some specimens, since tempering in oil gave high values of absorbed energy during impact and showed no significant changes in the low-temperature tempering. It follows that for SAE1045 steel the low tempering temperature cause a significant increase in material toughness regardless of the quenching medium, however for tempering SAE4140 steel in water makes it impossible to evaluate because of the cracks generated in the coolong and quenching in oil no improvement in toughness can be observed. / Este trabalho tem como principal objetivo a determinação do comportamento mecânico, mais especificamente a resistência ao impacto, de estruturas martensíticas baseadas em aços ao carbono e ligados. A preocupação principal é a resposta dessas ligas quando revenidas em temperaturas baixas (inferior a 180°C). Foram realizados os tratamentos térmicos de têmpera em água e óleo com o intuito de verificar a severidade do meio através dos ensaios de dureza, impacto, análise micrográfica e fractográfica. Os aços SAE1045 e SAE4140 também foram submetidos aos tratamentos térmicos de revenimento a baixas temperaturas, 100°C, 140°C e 180°C, para verificação do aumento da tenacidade e possíveis alterações microestruturais desses materiais. Foi verificada a maior temperabilidade do aço SAE4140 em relação ao aço SAE1045, em concordância com a literatura, através dos resultados de dureza e da análise micrográfica realizada. Na têmpera em óleo o aço SAE4140 apresentou uma microestrutura predominantemente martensítica o que gerou uma dureza superior a do aço SAE1045 que apresentou uma microestrutura de martensita com ilhas de perlita fina e ferrita. Nos revenimentos realizados foi constatado que para o aço SAE1045 ocorre um aumento de energia absorvida no impacto com o aumento da temperatura, e que estes revenimentos a baixa temperatura têm influências significativas sobre a tenacidade do material. Os revenimentos apresentam maiores aumentos de energia absorvida e expansão lateral no aço SAE1045 nas condições de têmpera em água do que na têmpera em óleo. Para o aço SAE4140 a têmpera em água (não muito usual na prática) gerou trincas em alguns corpos de prova, já a têmpera em óleo proporcionou valores elevados de energia absorvida no impacto e não mostrou alterações significativas nos revenimentos a baixa temperatura. Conclui-se que para o aço SAE1045 os revenimentos a baixa temperatura causam um aumento significativo na tenacidade do material independentemente do meio de têmpera; já para o aço SAE4140 a têmpera em água inviabiliza a avaliação devido as trincas geradas no resfriamento e para têmpera em óleo nenhuma melhoria na tenacidade pode ser observada.

This work deals with fatigue life and fractographycal analysis of plasma-nitrided and virgin specimen made of the low-alloy high-strength steel. Specimens were subjected to in-phase combined bending-torsion loading. The work is focused on three groups of problems. The first group of problems was associated with the fatigue life and its prediction. The objective was to examine a relationship between the presence of the nitrided layer and fatigue life. The application of surface layers has significantly improved the fatigue life in the high-cycle region. An extended comparison between classical and advanced multiaxial criteria was performed. Criterions proposed by Marin and Matake were found to be most precise. The second objective of this work was to examine a relationship between the loading ratio ( is the bending amplitude and is the torsion amplitude ) and the fracture surface topography in the highcycle fatigue. Properties of fracture surfaces were quantified by many roughness and fractal parameters. Many roughness parameters start to incrise rapidly above a critical value of the loading ratio zc = 0,5. The last part of this work deals with the fractographical analysis of fish-eye cracks that were formed in plasma-nitrided steel specimens under symetrical bending, symetrical torsion and biaxial in-phase bending-torsion combinations.

The goal of this study is to investigate the microstructure and microstructure-based fatigue (MSF) model of additively-manufactured (AM) metallic materials. Several challenges associated with different metals produced through additive manufacturing (Laser Enhanced Net Shaping – LENS®) have been addressed experimentally and numerically. Significant research efforts are focused on optimizing the process parameters for AM manufacturing; however, achieving a homogenous, defectree AM product immediately after its fabrication without postabrication processing has not been fully established yet. Thus, in order to adopt AM materials for applications, a thorough understanding of the impact of AM process parameters on the mechanical behavior of AM parts based on their resultant microstructure is required. Therefore, experiments in this study elucidate the effects of process parameters – i.e. laser power, traverse speed and powder feed rate – on the microstructural characteristics and mechanical properties of AM specimens. A majority of fatigue data in the literature are on rotation/bending test of wrought specimens; however, few studies examined the fatigue behavior of AM specimens. So, investigating the fatigue resistance and failure mechanism of AM specimens fabricated via LENS® is crucial. Finally, a microstructure-based MultiStage Fatigue (MSF) model for AM specimens is proposed. For calibration of the model, fatigue experiments were exploited to determine structure-property relations for an AM alloy. Additional modifications to the microstructurally-based MSF Model were implemented based on microstructural analysis of the fracture surfaces – e.g. grain misorientation and grain orientation angles were added to the MSF code.

No description available.