<p>An existing thermal model for laser melting and additive manufacturing (AM) was expanded to include phase transformation and hardness predictions for an alloy steel and coupled to experimental results. The study was performed on AISI 8620, a popular case-hardening, steel to understand microstructural and property effects for potential repair applications. The experimental samples were polished, etched with nital and picral for comparison, imaged, and Vicker’s microhardness was taken at 0.5 and 0.2 kg loads. The etched images revealed a transformation zone slightly larger than the melt zone in all cases including a gradient in transformation along the outer edges of the transformation zones. The microhardness measurements revealed that the lower energy cases provided a higher hardness in the melted region even after tempering due to multiple passes. But the overall hardness was higher than what is to be expected of a fully martensitic structure in AISI 8620. The phase transformation model qualitatively shows a similar microstructure where molten regions turn completely to martensite. The model also predicts a transformation zone larger than the melt pool size, as well as the transformation of pearlite but not ferrite near but not in melt pool. This observation is experimentally verified showing a heat affected zone where pearlite is clearly transformed but not ferrite outside the transformation zone comprised of complete martensite. The hardness model predicts a lower hardness than the experiments but is similar to what is expected based on published Jominy End Quench tests. The cases in the regime dominated by conductive heat transfer show good agreement with the predictions of melt pool shape and hardness by the thermal model. However, at higher powers and lower speeds, the fluid flow influenced the shape of the melt pool and the hat transfer in its vicinity, and the model was less accurate.</p>

No description available.

This dissertation research focuses on micromechanical modeling and simulations of two-phase heterogeneous materials exhibiting anisotropic and non-uniform microstructures with long-range spatial correlations. Completed work involves development of methodologies for realistic micromechanical analyses of materials using a combination of stereological techniques, two- and three-dimensional digital image processing, and finite element based modeling tools. The methodologies are developed via its applications to two technologically important material systems, namely, discontinuously reinforced aluminum composites containing silicon carbide particles as reinforcement, and boron modified titanium alloys containing in situ formed titanium boride whiskers. Microstructural attributes such as the shape, size, volume fraction, and spatial distribution of the reinforcement phase in these materials were incorporated in the models without any simplifying assumptions. Instrumented indentation was used to determine the constitutive properties of individual microstructural phases. Micromechanical analyses were performed using realistic 2D and 3D models and the results were compared with experimental data. Results indicated that 2D models fail to capture the deformation behavior of these materials and 3D analyses are required for realistic simulations. The effect of clustering of silicon carbide particles and associated porosity on the mechanical response of discontinuously reinforced aluminum composites was investigated using 3D models. Parametric studies were carried out using computer simulated microstructures incorporating realistic microstructural attributes. The intrinsic merit of this research is the development and integration of the required enabling techniques and methodologies for representation, modeling, and simulations of complex geometry of microstructures in two- and three-dimensional space facilitating better understanding of the effects of microstructural geometry on the mechanical behavior of materials.

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Les microfils métalliques polycristallins produits par étirage à froid présentent une résistance mécanique significative en faisant des candidats idéaux pour les renforts de composites. Des études antérieures sur des fils de nickel polycristallin pur ont montré une dépendance importante par rapport à la taille de la limite d'élasticité et de la résistance à la traction, ainsi que de la ductilité.Le but de cette étude est de comprendre cet effet de la taille dans les microfils de nickel pur polycristallin par analyse de diffraction des rayons X in-situ (DRX) et simulations de la plasticité cristalline par éléments finis (CPFE). Des essais de traction monotone et cyclique in-situ sous rayonnement synchrotron ont été réalisés sur des microfils de diamètres allant de 100 à 40 μm. Les fils étirés à 100 micromètres obtenus dans le commerce présentent une architecture cœur-coquille avec une texture de fibre <111> dominante dans le cœur et une texture à double fibre hétérogène <111> et <100> dans la coquille. La réduction de la taille de l'échantillon par polissage électrolytique conduit à des fils ayant une microstructure homogène, tandis que la réduction de la taille de l'échantillon par un étirage à froid supplémentaire conduit à des fils avec une texture plus intense tout en conservant l'architecture cœur-coquille.La limite d'élasticité et la résistance à la traction des fils électropolis augmentent avec la diminution du diamètre, tandis que la ductilité diminue avec la réduction du diamètre. Dans le cas des fils étirés à froid, on observe que la limite d'élasticité et la résistance à la traction, ainsi que la ductilité, augmentent avec la diminution du diamètre. L'analyse DRX indique une plasticité successive des familles de grains sous iso-déformation. Nous avons observé que le gradient de la texture du microfil active des mécanismes de déformation qui ne sont pas observés pour les microfils à texture homogène. Pour comprendre l'influence de différents paramètres microstructuraux, notamment l'influence de la texture cristallographique, une microstructure représentative 3D a été générée et des simulations CPFE ont été réalisées. Le comportement simulé moyen des différentes familles de grains (<111>, <100>) concorde bien avec les résultats expérimentaux. La simulation CPFE indique une hétérogénéité du champ de contrainte à travers la microstructure en présence d'un gradient de texture cristallographique.Nous montrons que la micro-texture (texture simple ou double texture) et leur dispersion spatiale (homogène ou architecturée) peuvent être utilisées comme stratégie de conception pour obtenir une microstructure optimale en fonction de l’ensemble désiré de propriétés mécaniques. / Polycrystalline metallic microwires produced by cold-drawing exhibit significant mechanical strength that make them ideal candidates for reinforcement of composites. Previous studies on polycrystalline pure nickel wires have indicated a significant size dependence of their yield and tensile strength as well as their ductility. The aim of this study is to understand these size effects by in-situ X-ray diffraction (XRD) analysis and crystal plasticity finite element (CPFE) simulations. In-situ monotonous and cyclic tensile tests under synchrotron radiation were carried on microwires with diameters ranging from 100 to 40 µm. The commercially obtained 100µm as-drawn wires exhibit a core-shell architecture with <111> fiber texture dominant in core and heterogeneous dual fiber texture <111> and <100> in the shell. Reduction of specimen size by electropolishing leads to wires having a homogeneous microstructure, whereas reduction of specimen size by further cold drawing leads to wires with a sharper texture while retaining the core-shell architecture.The yield and tensile strength of the electropolished wires increase with decreasing diameter, whereas the ductility decrease with decreasing diameter. In the case of cold-drawn wires, the yield and tensile strength, and also the ductility was observed to increase with decreasing diameter. The XRD analysis indicates successive yielding of grain families under iso-strain condition. The gradient in the texture of the microwire was seen to activate deformation mechanisms which are not seen for microwires with homogeneous texture. To understand the influence of different microstructural parameters, and notably the influence of crystallographic texture, 3D representative microstructure was generated and CPFE simulations were carried out. The simulated average behavior of different grain families (<111>, <100>) agrees well with the experimental results. The CPFE simulations indicate heterogeneity in stress field across the microstructure in the presence of a gradient in crystallographic texture.We show that the microstructure engineering of micro-texture components (single- or dual-texture) and their spatial spread (homogenous or architectured) can be used as design guidelines for obtaining optimal microstructure in accordance with desired set of mechanical properties.

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The performance of solid oxide fuel cells (SOFCs) at the cell and system levels is studied using computer simulation. At the cell level, a new model combining the cell micro and macro models is developed. Using this model, the microstructural variables of porous composite electrodes can be linked to the cell performance. In this approach, the electrochemical performance of porous composite electrodes is predicted using a micro-model. In the micro-model, the random-packing sphere method is used to estimate the microstructural properties of porous composite electrodes from the independent microstructural variables. These variables are the electrode porosity, thickness, particle size ratio, and size and volume fraction of electron-conducting particles. Then, the complex interdependency among the multi-component mass transport, electron and ion transports, and the electrochemical and chemical reactions in the microstructure of electrodes is taken into account to predict the electrochemical performance of electrodes. The temperature distribution in the solid structure of the cell and the temperature and species partial pressure distributions in the bulk fuel and air streams are predicted using the cell macro-model. In the macro-model, the energy transport is considered for the cell solid structure and the mass and energy transports are considered for the fuel and air streams. To demonstrate the application of the cell level model developed, entitled the combined micro- and micro-model, several anode-supported co-flow planar cells with a range of microstructures of porous composite electrodes are simulated. The mean total polarization resistance, the mean total power density, and the temperature distribution in the cells are predicted. The results of this study reveal that there is an optimum value for most of the microstructural variables of the electrodes at which the mean total polarization resistance of the cell is minimized. There is also an optimum value for most of the microstructural variables of the electrodes at which the mean total power density of the cell is maximized. The microstructure of porous composite electrodes also plays a significant role in the mean temperature, the temperature difference between the hottest and coldest spots, and the maximum temperature gradient in the solid structure of the cell. Overall, using the combined micro- and micro-model, an appropriate microstructure for porous composite electrodes to enhance the cell performance can be designed. At the system level, the full load operation of two SOFC systems is studied. To model these systems, the basic cell model is used for SOFCs at the cell level, the repeated-cell stack model is used for SOFCs at the stack level, and the thermodynamic model is used for the balance of plant components of the system. In addition to these models, a carbon deposition model based on the thermodynamic equilibrium assumption is employed. For the system level model, the first SOFC system considered is a combined heat and power (CHP) system that operates with biogas fuel. The performance of this system at three different configurations is evaluated. These configurations are different in the fuel processing method to prevent carbon deposition on the anode catalyst. The fuel processing methods considered in these configurations are the anode gas recirculation (AGR), steam reforming (SR), and partial oxidation reformer (POX) methods. The application of this system is studied for operation in a wastewater treatment plant (WWTP) and in single-family detached dwellings. The evaluation of this system for operation in a WWTP indicates that if the entire biogas produced in the WWTP is used in the system with AGR or SR fuel processors, the electric power and heat required to operate the plant can be completely supplied and the extra electric power generated can be sold to the electrical grid. The evaluation of this system for operation in single-family detached dwellings indicates that, depending on the size, location, and building type and design, this system with all configurations studied is suitable to provide the domestic hot water and electric power demands. The second SOFC system is a novel portable electric power generation system that operates with liquid ammonia fuel. Size, simplicity, and high electrical efficiency are the main advantages of this environmentally friendly system. Using a sensitivity analysis, the effects of the cell voltage at several fuel utilization ratios on the number of cells required for the SOFC stack, system efficiency and voltage, and excess air required for thermal management of the SOFC stack are studied.

The performance of solid oxide fuel cells (SOFCs) at the cell and system levels is studied using computer simulation. At the cell level, a new model combining the cell micro and macro models is developed. Using this model, the microstructural variables of porous composite electrodes can be linked to the cell performance. In this approach, the electrochemical performance of porous composite electrodes is predicted using a micro-model. In the micro-model, the random-packing sphere method is used to estimate the microstructural properties of porous composite electrodes from the independent microstructural variables. These variables are the electrode porosity, thickness, particle size ratio, and size and volume fraction of electron-conducting particles. Then, the complex interdependency among the multi-component mass transport, electron and ion transports, and the electrochemical and chemical reactions in the microstructure of electrodes is taken into account to predict the electrochemical performance of electrodes. The temperature distribution in the solid structure of the cell and the temperature and species partial pressure distributions in the bulk fuel and air streams are predicted using the cell macro-model. In the macro-model, the energy transport is considered for the cell solid structure and the mass and energy transports are considered for the fuel and air streams. To demonstrate the application of the cell level model developed, entitled the combined micro- and micro-model, several anode-supported co-flow planar cells with a range of microstructures of porous composite electrodes are simulated. The mean total polarization resistance, the mean total power density, and the temperature distribution in the cells are predicted. The results of this study reveal that there is an optimum value for most of the microstructural variables of the electrodes at which the mean total polarization resistance of the cell is minimized. There is also an optimum value for most of the microstructural variables of the electrodes at which the mean total power density of the cell is maximized. The microstructure of porous composite electrodes also plays a significant role in the mean temperature, the temperature difference between the hottest and coldest spots, and the maximum temperature gradient in the solid structure of the cell. Overall, using the combined micro- and micro-model, an appropriate microstructure for porous composite electrodes to enhance the cell performance can be designed. At the system level, the full load operation of two SOFC systems is studied. To model these systems, the basic cell model is used for SOFCs at the cell level, the repeated-cell stack model is used for SOFCs at the stack level, and the thermodynamic model is used for the balance of plant components of the system. In addition to these models, a carbon deposition model based on the thermodynamic equilibrium assumption is employed. For the system level model, the first SOFC system considered is a combined heat and power (CHP) system that operates with biogas fuel. The performance of this system at three different configurations is evaluated. These configurations are different in the fuel processing method to prevent carbon deposition on the anode catalyst. The fuel processing methods considered in these configurations are the anode gas recirculation (AGR), steam reforming (SR), and partial oxidation reformer (POX) methods. The application of this system is studied for operation in a wastewater treatment plant (WWTP) and in single-family detached dwellings. The evaluation of this system for operation in a WWTP indicates that if the entire biogas produced in the WWTP is used in the system with AGR or SR fuel processors, the electric power and heat required to operate the plant can be completely supplied and the extra electric power generated can be sold to the electrical grid. The evaluation of this system for operation in single-family detached dwellings indicates that, depending on the size, location, and building type and design, this system with all configurations studied is suitable to provide the domestic hot water and electric power demands. The second SOFC system is a novel portable electric power generation system that operates with liquid ammonia fuel. Size, simplicity, and high electrical efficiency are the main advantages of this environmentally friendly system. Using a sensitivity analysis, the effects of the cell voltage at several fuel utilization ratios on the number of cells required for the SOFC stack, system efficiency and voltage, and excess air required for thermal management of the SOFC stack are studied.