The impact phenomena of high velocity micron-size particles, although commonly considered and described as detrimental in numerous engineering applications, can be used in a beneficial way if properly understood and controlled. The Cold Gas Dynamic Spray (CGDS) process, known as a surface modification, repair and additive manufacturing process, relies on such high velocity impacts. In the process, solid particles are accelerated by a supersonic gas flow to velocities up to 1200 m/s and are simultaneously heated to temperatures lower than their melting point. When propelled under proper velocity and temperature, the particles can bond onto a target surface. This bonding is caused by the resulting interfacial deformation processes occurring at the contact interface. Hence, the process relies heavily on the gas/particle and particle/substrate interactions. Although numerous experimental and/or numerical studies have been performed to describe the phenomena occurring during particle flight and impact in the CGDS process, numerous phenomena remain poorly understood. First, the effect of substrate surface topographical condition on the particle deformation and ability to successfully adhere, i.e. atomically and/or mechanically, has not been thoroughly investigated such that its influence is not well understood. Another aspect of the process that is generating the largest gap between experimental and numerical studies in the field is the lack of particle in-flight temperature measurements. Obtaining such data has proven to be technically difficult. The challenges stem from the short particle flight time, low particle temperature and small particle size preventing the use of established thermal spray pyrometry equipment. Relatedly, lack of such measurements precludes a proper experimental study of the impact related phenomena at the particle/substrate interface. As a result, the effect of particle size dependent temperature on overall coating properties and atomic bonding relies currently on estimates. Finally, the effect of particle impact characteristics on interfacial phenomena, i.e. grain size and geometry, velocity/temperature, and oxide scale thickness, on adhesion and deformation upon single particle collision has also been scarcely studied for soft particle depositions on hard substrate. Hence, the current research work aims at studying fundamental aspects of particle/gas heat transfer and particle/substrate impact features in goals to improve the understanding of the CGDS process. Different surface preparation methods will be used to create various surface roughness and topographical features, to provide a clear understanding of the target surface state influence on coating formation and adhesion. Additionally, new equipment relying on novel technology, i.e. high-speed IR camera, will be utilized to obtain particle in-flight temperature readings with sequence recordings. Subsequently, the experimental particle in-flight temperature readings will be used to develop a computational fluid dynamics model in goals to validate currently used Nusselt number correlations and heat transfer equations. The particle size-dependent temperature effect on the particle’s elastic and plastic response to its impact with a targeted surface and its ability to successfully bond and form a coating will be studied experimentally. A thorough CFD numerical work, based on experimental findings, will be included to provide full impact characteristics (velocity, temperature, size and trajectory) of successfully deposited particles. Finally, the numerical results will be utilized in the ensuing study to correlate single particle deformation, adhesion and interfacial features to impact characteristics. A finite element model will be included to investigate the effect of particle size dependent temperature on single particle interfacial pressure, temperature and bonding ability.

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第20703号 / 工博第4400号 / 新制||工||1684(附属図書館) / 京都大学大学院工学研究科材料工学専攻 / (主査)教授 辻 伸泰, 教授 乾 晴行, 教授 安田 秀幸 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

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Cold spray is a unique additive manufacturing process, where a large number of ductile metal micro particles are deposited to create new surface coatings or free-standing structures. Metallic particles are accelerated through a gas stream, reaching velocities of over 1 km/s. Accelerated particles experience a high-strain-rate microscopic ballistic collisions against a target substrate. Large amounts of kinetic energy results in extreme plastic deformation of the particles and substrate. Though the cold spray process has been in use for decades, the extreme material science behind the deformation of particles has not been well understood due to experimental difficulties arising from the succinct spatial (10 μm) and temporal scales (10 ns). In this study, using a recently developed micro-ballistic method, the advanced laser induced projectile impact test (α-LIPIT), the dynamic behavior of micro-particles during the collision is precisely defined. We observe single aluminum 6061 alloy particles, approximately 20μm in diameter, impact and rebound off of a rigid target surface over a broad range of impact speeds, temperatures, and substrate oxide film thicknesses. Through observation of the collisions, we extract characteristic information of the dynamic response of particles as well as the relationship with various parameters (e.g. surrounding temperature, particle diameter, oxide thickness, and impact velocity). By impacting a polished aluminum 6061 alloy substrate we are able to mimic the collision events that occur during cold spray deposition. The connection between the temperature increase and the oxide thickness plays a role in theorizing the cause of unexpected phenomena, such as increased rebound energies at higher temperatures. Highly-controlled single particle impacts results, are provided to calibrate and improve computational simulations as well. This, in turn, can provide insight into the underlying material science behind the cold spray process.

This work presents a systematic study of the mechanochemical processes leading to chemical reactions occurring due to effects of high-strain-rate deformation associated with uniaxial strain and uniaxial stress impact loading in highly heterogeneous metal powder-based reactive materials, specifically compacted mixtures of Ti/Al/B powders. This system was selected because of the large exothermic heat of reaction in the Ti+2B reaction, which can support the subsequent Al-combustion reaction. The unique deformation state achievable by such high-pressure loading methods can drive chemical reactions, mediated by microstructure-dependent meso-scale phenomena. Design of the next generation of multifunctional energetic structural materials (MESMs) consisting of metal-metal mixtures requires an understanding of the mechanochemical processes leading to chemical reactions under dynamic loading to properly engineer the materials. The highly heterogeneous and hierarchical microstructures inherent in compacted powder mixtures further complicate understanding of the mechanochemical origins of shock-induced reaction events due to the disparate length and time scales involved. A two-pronged approach is taken where impact experiments in both the uniaxial stress (rod-on-anvil Taylor impact experiments) and uniaxial strain (instrumented parallel-plate gas-gun experiments) load configurations are performed in conjunction with highly-resolved microstructure-based simulations replicating the experimental setup. The simulations capture the bulk response of the powder to the loading, and provide a look at the meso-scale deformation features observed under conditions of uniaxial stress or strain. Experiments under uniaxial stress loading reveal an optimal stoichiometry for Ti+2B mixtures containing up to 50% Al by volume, based on a reduced impact velocity threshold required for impact-induced reaction initiation as evidenced by observation of light emission. Uniaxial strain experiments on the Ti+2B binary mixture show possible expanded states in the powder at pressures greater than 6 GPa, consistent with the Ballotechnic hypothesis for shock-induced chemical reactions. Rise-time dispersive signatures are consistently observed under uniaxial strain loading, indicating complex compaction phenomena, which are reproducible by the meso-scale simulations. The simulations show the prevalence of shear banding and particle agglomeration in the uniaxial stress case, providing a possible rationale for the lower observed reaction threshold. Bulk shock response is captured by the uniaxial strain meso-scale simulations and is compared with PVDF stress gauge and VISAR traces to validate the simulation scheme. The simulations also reveal the meso-mechanical origins of the wave dispersion experimentally recorded by PVDF stress gauges.

Materials intended for disposal of spent nuclear fuel require a particular combination of physical and chemical properties. The driving forces and mechanisms underlying the material’s behavior must be scientifically understood in order to enable modeling at the relevant time- and length-scales. The processes that determine the mechanical behavior of copper canisters and iron inserts, as well as the evolution of their mechanical properties, are strongly dependent on the properties of various defects in the bulk copper and iron alloys. The first part of the present thesis deals with precipitation in the cast iron insert. A nodular cast iron insert will be used as the inner container of the spent nuclear fuel. Precipitation is investigated by computing effective interaction energies for point defect pairs (solute–solute and vacancy–solute) in bcc iron using first-principles calculations. The main considered impurities in the iron matrix include 3sp (Si, P, S) and 3d (Cr, Mn, Ni, Cu) solute elements. By computing interaction energies possibility of formation of different second phase particles such as late blooming phases (LBPs) in the cast iron insert is evaluated. The second part is devoted to the fundamentals of dislocations and their role in plastic deformation of metals. Deformation of single-crystal copper under high strain rates is simulated by employing dislocation dynamics (DD) method to examine the effect of strain rate on mechanical properties as well as dislocation microstructure development. Creep deformation of copper canister at low temperatures is studied. The copper canister will be used in the long-term storage of spent nuclear fuel as the outer shell of the waste package to provide corrosion protection. A glide rate is derived based on the assumption that at low temperatures it is controlled by the climb rate of jogs on the dislocations. Using DD simulation creep deformation of copper at low temperatures is modeled by taking glide but not climb into account. Moreover, effective stresses acting on dislocations are computed using the data extracted from DD simulations. / <p>QC 20170428</p>

This investigation is focused on the understanding of mechanical and chemical reaction behaviors of stoichiometric mixtures of nano- and micro-scale aluminum and hematite (Fe2O3) powders dispersed in epoxy. Epoxy-cast Al+Fe2O3 thermite composites are an example of a structural energetic material that can simultaneously release energy while providing structural strength. The structural and energetic response of this material system is investigated by characterizing the mechanical behavior under high-strain rate and shock loading conditions. The mechanical response and reaction behavior are closely interlinked through deformation characteristics. It is, therefore, desirable to understand the deformation behavior up to and beyond failure and establish the necessary stress and strain states required for initiating chemical reactions. The composite s behavior has been altered by changing two main processing parameters; the reactants particle size and the relative volume fraction of the epoxy matrix. This study also establishes processing techniques necessary for incorporating nanometric-scale reactants into energetic material systems. The mechanochemical behavior of epoxy-cast Al+Fe2O3 composites and the influence of epoxy volume fraction have been evaluated for a variety of loading conditions over a broad range of strain rates, which include low-strain rate or quasistatic loading experiments (10-4 to 10-2 1/s), medium-strain rate Charpy and Taylor impacts (103 to 104 1/s), and high-strain rate parallel-plate impacts (105 to 106 1/s). In general, structural strength and toughness have been observed to improve as the volume fraction of epoxy decreases, regardless of the loading strain rate regime explored. Hugoniot experiments show damage occurring at approximately the same critical impact stress for compositions prepared with significantly different volume fractions of the epoxy binder phase. Additionally, Taylor impact experiments have indicated evidence for strain-induced chemical reactions, which subject the composite to large shear accompanied by temperature increase and associated softening, preceding these reactions. Overall, the work aims to establish an understanding of the microstructural influence on mechanical behavior and chemical reactivity exhibited by epoxy-cast Al+Fe2O3 materials when exposed to high stress and high-strain loading conditions. The understanding of fundamental aspects and the results of impact experiment measurements provide information needed for the design of structural energetic materials.

This research investigates the synthesis and manufacture of shape-memory polymer (SMP) systems for use in biomedical and commodity applications. The research centers on improving the mechanical properties of thermoset acrylate copolymers with memory properties at reasonable cost through various design and manufacturing techniques: high-strain polymer synthesis and radiation crosslinking. The research assesses combinations of linear monomers and a low density of crosslinker to characterize new functional materials and optimize emerging mechanical properties such as the glass transition temperature (Tg) and rubbery modulus (ER). Exploring materials with large recoverable strains, a model copolymer of photo-polymerized methyl acrylate (MA), isobornyl acrylate and crosslinker bisphenol A ethoxylate dimethacrylate was shown to strain above 800%, twice the previously published value for SMPs, and recover fully. In the quest to maximize fully recoverable strains, a new hybrid molecule nicknamed Xini, which serves as both an initiator and a crosslinker, was also theorized, synthesized, polymerized into SMP networks and characterized. In the past, thermoset SMPs were made into complex shapes using expensive top-down techniques. A block of polymer was made and custom machining was required to craft complex parts. This prohibited devices in cost-competitive commodity application spaces. This research has proposed and validated a new method for accurately tuning the thermomechanical properties of network acrylates with shape-memory properties: Mnemosynation, eponymously named for the Greek goddess of memory. This novel manufacturing process imparts long term 'memory' on an otherwise amorphous thermoplastic material utilizing radiation-induced covalent crosslinking, and can be likened to Vulcanization, which imparts strength on natural rubber utilizing sulfur crosslinks. Adjustment of ER in the range from below 1 MPa to above 13 MPa has been demonstrated. ER was tailored by varying both radiation dose between 5 and 300 kGy and crosslinker concentration between 1.00 and 25.0 wt%. Tg manipulation was demonstrated between 23 ˚C and 70 ˚C. Mnemosynation combines advances in radiation grafting and acrylic SMP synthesis to enable both traditional plastics processing (blow molding, injection molding, etc.) and control of thermoset shape-memory properties. Combining advances in both high strain polymer synthesis and radiation crosslinking, a new paradigm in SMP composites manufacture-namely, that materials can be designed to enhance strain capacity at moderate stress, rather than maximum strength-was established. Various fibers with very different mechanical properties were impregnated with SMPs and thermo-mechanically assessed to develop an understanding of the technical parameters necessary to craft self-adjusting, multi-actuated, SMP-fiber composite orthopedic casts. This exploration syncs with the overarching aim of the research, which is to understand the fundamental scientific drivers necessary to enable new devices mass-manufactured from acrylate copolymers and optimize their emerging mechanical properties.

Deliberate and accidental explosions along with the heightened risk of loss of life and property damage during such events have highlighted the need for research in the behaviour of materials under high strain rates. Where an extensive body of research is available on steel and concrete structures, little to no details on how to address the design or retrofitting of wood structures subjected to a blast threat are available. Studies reported in the literature that focused on full scale light-frame wood structures did not quantify the increase in capacity due to the dynamic loading while the studies that did quantify the increase mostly stems from small clear specimens that are not representative of the behaviour of structural size members with defects. Tests on larger-scale specimens have mostly focused on the material properties and not the structural behaviour of subsystems. Advancements in design and construction techniques have greatly contributed to the emergence of taller and safer wood structures which increase potential for blast threat. This thesis presents results on the flexural behaviour of light-frame wood stud walls subjected to shock wave loading using the University of Ottawa shock tube. The emphasis is on the overall behaviour of the wall subsystem, especially the interaction between the sheathing and the studs through the nailed connection. The approach employed in this experimental program was holistic, where the specimens were investigated at the component and the subsystem levels. Twenty walls consisting of 38 mm x 140 mm machine stress-rated (MSR) studs spaced 406 mm on center and sheathed with two different types and sheathing thicknesses were tested to failure under static and dynamic loads. The experimental results were used to determine dynamic increase factors (DIFs) and a material predictive model was validated using experimental data. The implications of the code are also discussed and compared to the experimental data. Once validated, an equivalent single-degree-of-freedom (SDOF) model incorporating partial composite action was used to evaluate current analysis and design assumptions. The results showed that a shock tube can effectively be used to generate high strain-rate flexural response in wood members and that the material predictive model was found suitable to effectively predict the displacement resulting from shock wave loading. Furthermore, it was found that current analysis and design approaches overestimated the wall displacements.

Η σφυρηλάτηση με βολή σωματιδίων (shot peening) είναι μία επιφανειακή κατεργασία που πραγματοποιείται με σκοπό την αύξηση της αντοχής μεταλλικών υλικών και εφαρμόζεται στο τελευταίο στάδιο της γραμμής παραγωγής. Η αύξηση της αντοχής επιτυγχάνεται με την ανάπτυξη θλιπτικών παραμενουσών τάσεων κοντά στην επιφάνεια του υλικού έπειτα από την κρούση σωματιδίων με υψηλές ταχύτητες. Η ανάπτυξη θλιπτικών παραμενουσών τάσεων αυξάνει την αντοχή σε κόπωση, σε εργοδιάβρωση, καθώς και σε άλλες μηχανικές καταπονήσεις και επιτρέπει την μείωση του βάρους σχεδιάζοντας διατομές με μικρότερο πάχος. Στην παρούσα Διδακτορική Διατριβή παρουσιάζεται μια ολοκληρωμένη αριθμητική προσομοίωση της κατεργασίας και εξετάζεται η μηχανική συμπεριφορά των υπό κατεργασία υλικών σε υψηλούς ρυθμούς καταπόνησης. Συγκεκριμένα η μεθοδολογία που αναπτύσσεται περιλαμβάνει την ανάπτυξη ενός αριθμητικού προτύπου για την προσομοίωση της κατεργασίας της σφυρηλάτησης με βολή σωματιδίων και τον υπολογισμό των αποτελεσμάτων της στο υλικό. Τα βήματα που ακολουθηθήκαν για την ανάπτυξη του αριθμητικού προτύπου είναι, α) ο χαρακτηρισμός του κράματος αλουμινίου 7449-Τ7651 σε υψηλούς ρυθμούς καταπόνησης μέσω της πειραματικής διάταξης Split Hopkinson Bar που σχεδιάστηκε και κατασκευάστηκε στο Εργαστήριο Τεχνολογίας και Αντοχής Υλικών, β) η ανάπτυξη βοηθητικών επιμέρους αριθμητικών μοντέλων, γ) η ανάπτυξη κινηματικών μοντέλων προσομοίωσης της ροής των σωματιδίων, δ) η ανάπτυξη κριτηρίων και η εφαρμογή τους για τον υπολογισμό του ελαχίστου απαιτούμενου αριθμού σωματιδίων για την προσομοίωση, καθώς και των θέσεων κρούσης, ε) η ανάπτυξη ενός αριθμητικού προτύπου πλήρους γεωμετρίας της πλάκας για την κρούση του απαιτούμενου αριθμού σωματιδίων και στ) η πειραματική επαλήθευση του αριθμητικού προτύπου. Με το αριθμητικό πρότυπο που αναπτύχτηκε υπολογίστηκαν τα αποτελέσματα της κατεργασίας της σφυρηλάτησης με βολή σωματιδίων στο υλικό και επιβεβαιώθηκαν μέσω συγκρίσεων με αντίστοιχα πειραματικά αποτελέσματα. Αποτελέσματα της κατεργασίας εκτός από τις παραμένουσες τάσεις αποτελούν και η πλαστική παραμόρφωση, η σκληρότητα, η επιφανειακή τραχύτητα και κατ' επέκταση ο συντελεστής έντασης τάσης. Στη συνέχεια, πραγματοποιήθηκε μια παραμετρική μελέτη για την επίδραση της διαμέτρου, της ταχύτητας και της γωνίας κρούσης στην ανάπτυξη των παραμενουσών τάσεων. Επίσης το αριθμητικό πρότυπο επαληθεύτηκε και για άλλα μεταλλικά υλικά. / Shot peening is a surface treatment process that is performed to increase the strength of metallic materials and is applied to the last stage of the production line (post manufacturing process). The increase in strength is achieved by the developed compressive residual stresses near the surface and the subsurface of the treated material after the impact of small diameter particles with high speeds. The developed compressive residual stresses increases the fatigue strength, the mechanical performance of the component under stress corrosion cracking (SCC), under higher stresses and allows lighter structure design. This PhD thesis presents a comprehensive numerical simulation of the Shot peening process and includes a comprehensive study of the mechanical behaviour of treated materials under high strain rates of deformation. Specifically, the methodology developed includes the development of a comprehensive numerical model to simulate Shot peening treatment and calculate the results on the treated material. The steps followed for the development of the numerical model are: a) the characterization of the Aluminium alloy 7449-T7651 at high strain rates using a Split Hopkinson Bar apparatus designed and built at the Laboratory of Technology and Strength of Materials, b) the development of auxiliary partial numerical models, c) the development of a kinematic simulation model for the analysis of the flow particles, d) the development and the application of two criteria for the successful calculation of the minimum number of particles that required for the simulation, and the impact positions e) the development of a numerical model describing the full plate geometry for the impact of the minimum number of particles required and f) the experimental verification of the numerical model. The process outcomes and results on the treated material were calculated by the numerical model developed. The numerical results that were calculated for the threaded material were confirmed by comparison with experimental results. Treatment results include the residual stresses, the plastic deformation, hardness, surface roughness, and hence the stress concentration factor. A parametric study on the effect of the diameter, speed and angle of impact to the development of residual stresses was performed. The numerical model was also verified for a number of other metallic materials.