The high strength, light weight, and flexibility of fabric protection systems makes them the preferred solution for a number of ballistic applications. Examples include body armor, fan blade containment for jet engines, and orbital debris shielding. In general, these protection systems employ plain woven fabric, most suitable for flat or gently curved geometries. Highly curved surfaces, such as personnel extremities, may be more effectively protected using fabrics of different weaves. This dissertation presents the first numerical model developed to simulate ballistic impacts into plain, harness satin, twill, and basket weave fabrics. It extends previous work on hybrid particle-finite element methods developed for fabric modeling. The extended formulation closely replicates the tensile load response and contact-impact dynamics of highly flexible yarns, by generalizing the kinematic model and density interpolation used in previous work. The formulation has been validated in three dimensional simulations of impact experiments conducted to investigate the effects of weave type on fabric ballistic performance. / text

A popular way to reduce weight in industrial products without compromising the strength or stiffness is to replace components made of metal by plastics that have been reinforced by glass fibers. When fibers are introduced in a plastic, the resulting composite usually becomes anisotropic, which makes it much more complex to work with in simulation software. This thesis looks at modeling of such a composite using the multi-scale material modeling tool Digimat. An injection molding simulation of a brush cutter casing made of a short fiber reinforced plastic has been performed in order to obtain information about the glass fiber orientations, and thus the anisotropy, in each material point. That information has then been transferred over from the injection mesh to the structural mesh via a mapping routine. An elasto-viscoplastic material model with failure has been employed and calibrated against experimental data to find the corresponding material parameters. Lastly, a finite element analysis simulating a drop test has been performed. The results from the analysis have been compared with a physical drop test in order to evaluate the accuracy of the methodology used. The outcome has been discussed, conclusions have been drawn and suggestions for further studies have been presented.

Abstract The cold spray process is an additive manufacturing technology primarily suited for ductile metals, and mainly utilized in coating surfaces, manufacturing of freeform parts and repair of damaged components. The process involves acceleration of solid micro-particles in a supersonic gas flow and coating build-up by bonding upon high velocity impact onto a substrate. Coating deposition relies on the kinetic energy of the particles. The main objective of this study was to investigate the mechanics of polymer cold spray process and deformation behavior of polymers to improve technological implementation of the process. A finite element model was created to simulate metal particle impact for copper and aluminum. These results were compared to the numerical and experimental results found in the literature to validate the model. This model was then extended to cover a wide range of impact conditions, in order to reveal the governing mechanisms of particle impact and rebound during cold spray. A systematic analysis of a single high-density polyethylene particle impacting on a semi-infinite high density polyethylene substrate was carried out for initial velocities ranging between 150m/s and 250m/s by using the finite element analysis software ABAQUS. A series of numerical simulations were performed to study the effect of a number of key parameters on the particle impact dynamics. These key parameters include: particle impact velocity, particle temperature, particle diameter, and particle density, composition of the polyethylene particle, surface composition and the thickness of a polyethylene film on a hard metal substrate. The effect of these parameter variations were quantified by tracking the particle temperature, deformation, plastic strain and rebound kinetic energy. The variation of these parameters helped define a window of deposition where the particle is mostly likely to adhere to the substrate.

Achieving light weight armor design has become an important engineering challenge in the last three decades. As weapons becoming highly sophisticated, so does the ammunition, potential targets have to be well protected against such threats. In order to provide mobility, light and effective armor protection materials should be used. In this thesis, numerical simulation of the silicon carbide armor backed by KevlarTM composite and orthogonally impacted by 7.62mm armor piercing (AP) projectile at an initial velocity of 850 m/s is analyzed by using AUTODYN hydrocode. As a first step, ceramic material behavior under impact conditions is validated numerically by comparing the numerical simulation result with the test result which is obtained from the literature. Then, different numerical simulations are performed by changing the backing material thickness, i.e. 2, 4, 6 and 8mm, while the thickness of the ceramic is held constant, i.e. 8mm. At the end of the simulations, optimum ceramic/composite thickness ratio is sought. The results of the simulations showed that for the backing thickness values of 4, 6 and 8mm, the projectile could not perforate the armor system. On the contrary, the projectile could penetrate and perforate the armor system for the backing thickness value of 2mm and it has still some residual velocity. From these results, it is inferred that the optimum ceramic/composite thickness ratio is equal to about 2 for the silicon carbide and kevlar configuration.

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<p> The Selective Laser Melting (SLM) process is a manufacturing technique that facilitates the  production of metallic parts with complex geometries and reduces both materials waste and lead  time. The high tunability of the process parameters in SLM allows the design of the as-built part’s  characteristics, such as controlled microstructure formation, residual stresses, presence of pores,  and lack of fusion. The main parameter in the SLM process that influences these parts’  characteristics is the transient temperature field resulting from the laser-matter interaction.  Nanosecond pulsed lasers in SLM have the advantage of enabling rapid and localized heating and  cooling that make the formation of ultrafine grains possible. This work shows how different pulse  durations can change the near-surface microstructure and overall mechanical properties of metallic  parts. The nanosecond pulses can melt and resolidify aluminum parts’ near-surface region to form nanograined gradient structures with yield strengths as high as 250.8 MPa and indentation  strengths as high as 725 MPa, which are comparable to some steel's mechanical properties. Knowing that the nanosecond pulsed lasers cause microstructure refinement for high-purity metals,  the microstructure variations effects were also investigated for the cast iron alloy. Cast iron was  used alone and mixed with born or boron nitride powders to induce the precipitation of  strengthening phases only enabled under high cooling rates. Although producing parts with  superior mechanical properties and controlling the precipitation of strengthening phases, the SLM  process with nanosecond pulsed lasers is still accompanied by defects formation, mainly explained  by the large thermal gradients, keyhole effect, reduced melt pool depth, and rapid cooling rates.  Ideally, a smooth heating rate able to sinter powder grains, facilitating the heat flow through the  heat-affected zone, followed by a sharper heating rate that generates a fully molten region, but  minimizes ablation at the same time are targeted to reduce the porosity and lack of fusion. Then, a  sharp cooling rate that can increase the nucleation rate, consequently refining the final  microstructure is targeted in the production of strong materials in SLM with pulsed lasers. This  work is the pioneer in controlling the transient temperature field during the heating and cooling  stages in pulsed laser processing. The temperature field control capability by shaping a nanosecond  laser pulse in the time domain affecting defects formation, residual strains, and microstructure was  achieved, opening a wide research niche in the additive manufacturing field.  </p>