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This study focuses on developing explicit analytical and numerical process models for mechanical micro-machining of heterogeneous materials. These models are used to select suitable process parameters for preparing and micro-machining of these advanced materials. The material system studied in this research is Magnesium Metal Matrix Composites (Mg-MMCs) reinforced with nano-sized and micro-sized silicon carbide (SiC) particles. This research is motivated by increasing demands of miniaturized components with high mechanical performance in various industries. Mg-MMCs become one of the best candidates due to its light weight, high strength, and high creep/wear resistance. However, the improved strength and abrasive nature of the reinforcements bring great challenges for the subsequent micro-machining process. Systematic experimental investigations on the machinability of Mg-MMCs reinforced with SiC nano-particles have been conducted. The nanocomposites containing 5 Vol.%, 10 Vol.% and 15 Vol.% reinforcements, as well as pure magnesium, are studied by using the Design of Experiment (DOE) method. Cutting forces, surface morphology and surface roughness are characterized to understand the machinability of the four materials. Based on response surface methodology (RSM) design, experimental models and related contour plots have been developed to build a connection between different materials properties and cutting parameters. Those models can be used to predict the cutting force, the surface roughness, and then optimize the machining process. An analytical cutting force model has been developed to predict cutting forces of MgMMCs reinforced with nano-sized SiC particles in the micro-milling process. This model is iv different from previous ones by encompassing the behaviors of reinforcement nanoparticles in three cutting scenarios, i.e., shearing, ploughing and elastic recovery. By using the enhanced yield strength in the cutting force model, three major strengthening factors are incorporated, including load-bearing effect, enhanced dislocation density strengthening effect and Orowan strengthening effect. In this way, the particle size and volume fraction, as significant factors affecting the cutting forces, are explicitly considered. In order to validate the model, various cutting conditions using different size end mills (100 µm and 1 mm dia.) have been conducted on Mg-MMCs with volume fraction from 0 (pure magnesium) to 15 Vol.%. The simulated cutting forces show a good agreement with the experimental data. The proposed model can predict the major force amplitude variations and force profile changes as functions of the nanoparticles’ volume fraction. Next, a systematic evaluation of six ductile fracture models has been conducted to identify the most suitable fracture criterion for micro-scale cutting simulations. The evaluated fracture models include constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of a user material subroutine (VUMAT), these fracture models are implemented into a Finite Element (FE) orthogonal cutting model in ABAQUS/Explicit platform. The local parameters (stress, strain, fracture factor, velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. Results indicate that by coupling with the damage evolution, the capability of Johnson-Cook and Bao-Wierzbicki can be further extended to predict accurate chip morphology. Bao-Wierzbiki-based coupling model provides the best simulation results in this study. v The micro-cutting performance of MMCs materials has also been studied by using FE modeling method. A 2-D FE micro-cutting model has been constructed. Firstly, homogenized material properties are employed to evaluate the effect of particles’ volume fraction. Secondly, micro-structures of the two-phase material are modeled in FE cutting models. The effects of the existing micro-sized and nano-sized ceramic particles on micro-cutting performance are carefully evaluated in two case studies. Results show that by using the homogenized material properties based on Johnson-Cook plasticity and fracture model with damage evolution, the micro-cutting performance of nano-reinforced Mg-MMCs can be predicted. Crack generation for SiC particle reinforced MMCs is different from their homogeneous counterparts; the effect of micro-sized particles is different from the one of nano-sized particles. In summary, through this research, a better understanding of the unique cutting mechanism for particle reinforced heterogeneous materials has been obtained. The effect of reinforcements on micro-cutting performance is obtained, which will help material engineers tailor suitable material properties for special mechanical design, associated manufacturing method and application needs. Moreover, the proposed analytical and numerical models provide a guideline to optimize process parameters for preparing and micro-machining of heterogeneous MMCs materials. This will eventually facilitate the automation of MMCs’ machining process and realize high-efficiency, high-quality, and low-cost manufacturing of composite materials.

Cette thèse porte sur la commande de réseaux multi-terminaux à courant continu (MTDC) basés sur des convertisseurs multiniveaux modulaires (MMCs).Tout d’abord, notre attention se focalise sur l'énergie stockée en interne dans le MMC qui constitue un degré de liberté additionnel apporté par sa topologie complexe. Afin d’en tirer le meilleur parti, les limites de l’énergie interne sont formulées mathématiquement.Afin de maîtriser la dynamique de la tension DC, l’utilisation de ce nouveau degré de liberté s’avère d’une grande importance. Par conséquent, une nouvelle de stratégie de commande, nommée «Virtual Capacitor Control», est proposée. Cette nouvelle méthode de contrôle permet au MMC de se comporter comme s’il possédait un condensateur de taille réglable aux bornes, contribuant ainsi à l’atténuation des fluctuations de la tension DC.Enfin, la portée de l’étude est étendue au réseau MTDC. L'un des défis majeurs pour un tel système est de faire face à une perte soudaine d'une station de convertisseur qui peut entraîner une grande variation de la tension du système. A cet effet, la méthode de statisme de tension est la plus couramment utilisée. Cependant, l'analyse montre que l'action de contrôle souhaitée risque de ne pas être réalisée lorsque la marge disponible de réserve de puissance du convertisseur est insuffisante. Nous proposons donc une nouvelle structure de contrôle de la tension qui permet de fournir différentes actions en fonction du signe de l'écart de la tension suite à une perturbation, associée à un algorithme qui détermine les paramètres de statisme en tenant compte du point de fonctionnement et de la réserve disponible à chaque station. / The scope of this thesis includes control and management of the Modular Multilevel Converter (MMC)-based Multi-Terminal Direct Current (MTDC).At first, our focus is paid on the internally stored energy, which is the important additional degree of freedom brought by the complex topology of MMC. In order to draw out the utmost of this additional degree of freedom, an in-depth analysis of the limits of this internally stored energy is carried out, and they are mathematically formulated.Then, this degree of freedom of the MMC is used to provide a completely new solution to improve the DC voltage dynamics. A novel control strategy, named Virtual Capacitor Control, is proposed. Under this control, the MMC behaves as if there were a physical capacitor whose size is adjustable. Thus, it is possible to virtually increase the equivalent capacitance of the DC grid to mitigate the DC voltage fluctuations in MTDC systems.Finally, the scope is extended to MMC-based MTDC grid. One of the crucial challenges for such system is to cope with a sudden loss of a converter station which may lead to a great variation of the system voltage. The voltage droop method is commonly used for this purpose. The analysis shows that the desired control action may not be exerted when the available headroom of the converter stations are insufficient. We thus propose a novel voltage droop control structure which permits to provide different actions depending on the sign of DC voltage deviation caused by the disturbance of system voltage as well as an algorithm that determines the droop parameters taking into account the operating point and the available headroom of each station.

The corrosion behaviour of cast Al-Mg alloy A535 and its composites containing 10 wt.% and 15 wt.% fly ash, and 10 wt.% hybrid reinforcement (5 wt.% fly ash + 5 wt.% SiC) was investigated using weight-loss and electrochemical corrosion tests, optical microscopy, Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). The tests were conducted in fresh water collected from the South Saskatchewan River and 3.5 wt.% NaCl solution at room temperature. The pH of the salt solution varied from 3 to 9. For comparison, two other aluminum alloys, AA2618 and AA5083-H116, were tested in the same electrolytes. The results of the weight-loss corrosion test showed that unreinforced A535 alloy had a lower corrosion rate in fresh water and seawater environments than the composites at all the tested pH values. The corrosion rate of the composites increased with increasing fly ash content. As expected, the corrosion rates of A535 alloy and the composites tested in fresh water were lower than those in salt solution. The results of the potentiodynamic and cyclic polarization electrochemical tests showed that the corrosion potential (Ecorr) and pitting potential (Epit) of the alloy were more positive than those of the composites. The corrosion and pitting potentials of the composites became more negative (active) with increasing fly ash content. The composites showed more positive (noble) repassivation or protection potential (Erp) than the matrix alloy, with the positivity increasing with fly ash content. Analysis of the electrochemical noise data showed that pitting corrosion was the dominant mode of corrosion for the alloy in 3.5 wt.% NaCl solution. Optical microscopy and SEM revealed that Mg2Si phase and Al-Mg intermetallics corroded preferentially to the matrix. The EDS data indicated that the protective oxide film formed on A535 contained Al2O3 and MgO.

The corrosion behaviour of cast Al-Mg alloy A535 and its composites containing 10 wt.% and 15 wt.% fly ash, and 10 wt.% hybrid reinforcement (5 wt.% fly ash + 5 wt.% SiC) was investigated using weight-loss and electrochemical corrosion tests, optical microscopy, Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). The tests were conducted in fresh water collected from the South Saskatchewan River and 3.5 wt.% NaCl solution at room temperature. The pH of the salt solution varied from 3 to 9. For comparison, two other aluminum alloys, AA2618 and AA5083-H116, were tested in the same electrolytes. The results of the weight-loss corrosion test showed that unreinforced A535 alloy had a lower corrosion rate in fresh water and seawater environments than the composites at all the tested pH values. The corrosion rate of the composites increased with increasing fly ash content. As expected, the corrosion rates of A535 alloy and the composites tested in fresh water were lower than those in salt solution. The results of the potentiodynamic and cyclic polarization electrochemical tests showed that the corrosion potential (Ecorr) and pitting potential (Epit) of the alloy were more positive than those of the composites. The corrosion and pitting potentials of the composites became more negative (active) with increasing fly ash content. The composites showed more positive (noble) repassivation or protection potential (Erp) than the matrix alloy, with the positivity increasing with fly ash content. Analysis of the electrochemical noise data showed that pitting corrosion was the dominant mode of corrosion for the alloy in 3.5 wt.% NaCl solution. Optical microscopy and SEM revealed that Mg2Si phase and Al-Mg intermetallics corroded preferentially to the matrix. The EDS data indicated that the protective oxide film formed on A535 contained Al2O3 and MgO.

In this thesis, a novel in-situ method for incorporating nanoscale ceramic particles into metal has been developed. The ceramic phase is introduced as an organic-polymer precursor that pyrolyzes in-situ to produce a ceramic phase within the metal melt. The environment used to shield the melt from burning also protects the organic precursor from oxidation. The evolution of volatiles (predominantly hydrogen) as well as the mechanical stirring causes the polymer particles to fragment into nanoscale dispersions of a ceramic phase. These “Polymer-based In-situ Process-Metal Matrix Composites” (PIP-MMCs) are likely to have great generality, because many different kinds of organic precursors are commercially available, for producing oxides, carbides, nitrides, and borides. Also, the process would permit the addition of large volume fractions of a ceramic phase, enabling nanostructural design, and production of MMCs with a wide range of mechanical properties, meant especially for high temperature applications. An important and noteworthy feature of the present process, which distinguishes it from other methods, is that all the constituents of the ceramic phase are built into the organic molecules of the precursor (e.g., polysilazanes contain silicon, carbon, and nitrogen); therefore, a reaction between the polymer and the host metal is not required to produce the dispersion of the refractory phase. The polymer precursor powder, with a mean particle size of 31.5 µm, was added equivalent to 5 and 10 weight % of the melt (pure magnesium) by a liquid metal stir-casting technique. SEM and OM microstructural observations show that in the cast structure the pyrolysis products are present in the dendrite boundary region in the form of rod/platelets having a thickness of 100 to 200 nm. After extrusion the particles are broken down into fine particles, having a size that is comparable to the thickness of the platelets, in the 100 to 200 nm range, and are distributed more uniformly. In addition, limited TEM studies revealed the formation of even finer particles of 10-50 nm. X-ray diffraction analysis shows the presence of a small quantity of an intermetallic phase (Mg2Si) in the matrix, which is unintended in this process. There was a significant improvement in mechanical properties of the PIP-MMCs compared to the pure Mg. These composites showed higher macro-and micro-hardness. The composite exhibited better compressive strength at both room temperature and at elevated temperatures. The increase in the density of PIP-composites is less than 1% of Mg. Five weight percent of the precursor produced a two-fold increase in the room-temperature yield strength and reduced the steady state creep rate at 723 K by one to two orders of magnitude. PIP-MMCs showed higher damping capacity and modulus compared to pure Mg, with the damping capacity increasing by about 1.6 times and the dynamic modulus by 11%-16%. PIP-composites showed an increase in the sliding wear resistance by more than 25% compared to pure Mg.

Modular multilevel converters (MMCs) are the preferred converter solution in flexible ac transmission systems (FACTS) and high-voltage direct current (HVDC) applications. This is due to the high quality of the voltage and current signals, lower overall losses, and fewer problems with switching-related EMI. However, without an efficient and fast data recording system, the sampled data from current and voltage measurement boards can cause long latencies in the control system and make it difficult to analyze the operation of MMCs. In this thesis, a filed programmable gate array (FPGA)-based closed-loop control, and a high-speed data recording system is developed for a low-power singlephase MMC prototype. In the prototype, a data-transmission scheme based on the RS485 (TIA/EIA- 485) standard exists. This protocol offers a robust solution for transmitting data over noisy environments. A direct memory access (DMA) scheme is utilized to transmit sampled data from the programmable logic (PL) to the processing subsystem (PS) in the Zynq-7000 SOC. Moreover, an asymmetric multiprocessing (AMP) mechanism was implemented on the two processor cores in the PS. The first processor controls the power transmission to and from the power grid, and the second processor runs the ethernet application to transmit sampled data to the computer using MATLAB. For the closed-loop control of this MMC prototype, a phase-locked loop (PLL), a proportional resonant (PR) current controller, and an energy control loop for capacitor voltage balancing and control are implemented. The results showed that the output power of this single-phase MMC prototype is under control and each sub-module capacitor voltage is balanced and charged to the desired value. The sampled data can be recorded from the computer through the implemented data recording system at 25.6Mbps. Moreover, a dynamic oscilloscope function is developed in MATLAB using this online data recording scheme. / Modulära multilevel-omvandlare (MMC) är den föredragna omvandlarlösningen i flexibla växelströmstransmissionssystem (FACTS) och applikationer med högspänningslikström (HVDC). Detta beror på den höga kvaliteten på spännings- och strömsignalerna, lägre totala förluster och färre problem med omkopplingsrelaterad EMI. Utan ett effektivt och snabbt dataregistreringssystem kan dock samplade data från ström- och spänningsmätkort orsaka långa latenser i styrsystemet och göra det svårt att analysera driften av MMC:er. I denna avhandling utvecklas en FPGA-baserad styrning med sluten slinga och ett höghastighetsdataregistreringssystem för en lågeffekts enfas MMCprototyp. I prototypen finns ett dataöverföringssystem baserat på standarden RS485 (TIA/EIA-485). Detta protokoll erbjuder en robust lösning för att överföra data över bullriga miljöer. Ett schema för direkt minnesåtkomst (DMA) används för att överföra samplade data från den programmerbara logiken (PL) till bearbetningsundersystemet (PS) i Zynq-7000 SOC. Dessutom implementerades en asymmetrisk multiprocessing (AMP)-mekanism på de två processorkärnorna i PS. Den första processorn styr kraftöverföringen till och från elnätet, och den andra processorn kör ethernetapplikationen för att överföra samplade data till datorn med MATLAB. För styrning med sluten slinga av denna MMC-prototyp implementeras en faslåst slinga (PLL), en proportionell resonansströmkontroller (PR) och en energikontrollslinga för balansering och kontroll av kondensatorspänning. Resultaten visade att uteffekten från denna enfasiga MMC-prototyp är under kontroll och varje undermoduls kondensatorspänning är balanserad och laddad till önskat värde. Samplade data kan spelas in från datorn genom det implementerade dataregistreringssystemet vid 25,6 Mbps. Dessutom utvecklas en dynamisk oscilloskopfunktion i MATLAB med hjälp av detta onlinedataregistreringsschema.