La mise en forme de l'alliage d'aluminium de corroyage 7075 de pièces fonctionnelles à géométrie complexe se fait la plupart du temps par usinage. Pour un nombre de pièces important, le coût peut être réduit en réalisant une ébauche par forgeage. Il est cependant plus intéressant de réaliser une ébauche proche des dimensions finales pour limiter l'usinage (aspect near-net-shape). Pour mettre en forme une pièce à géométrie complexe en une seule étape, la résistance à la déformation de la matière doit être suffisamment faible. Cette faible déformation nécessite la génération d'une phase liquide, ce qui introduit des défauts dans l'alliage de corroyage tels que la fissuration à chaud, porosité, retassure, retrait important, macroségrégation solide-liquide. L'apparition de ces défauts peut être réduite en limitant la fraction volumique de la phase liquide à 0.1. AA 7075 étant particulièrement sensible à la fissuration à chaud, un faible retrait est un atout. Nous choisirons le procédé RAP pour obtenir une matière globulaire semi-solide. Ce procédé utilise la recristallisation d'une matière extrudée pour réaliser une matière qui a un comportement rhéofluidifiant-thixotrope. Le procédé de mise en forme de cette matière semi-solide globulaire à faible phase liquide est le thixoforgeage. Des essais de chauffage de la matière extrudée et de filage permettront d'étudier l'influence des divers paramètres du procédé sur l'effort de mise en forme et sur la qualité des pièces produites. Nous adapterons les paramètres de chauffage et de mise en forme sur un outillage spécialement conçu pour le thixoforgeage pour des pièces à géométrie simple et pour des pièces à géométrie complexe. Une étude de l'influence des paramètres sur les caractéristiques mécaniques et sur la qualité des pièces a montré le très bon potentiel de mise en forme de AA 7075 par thixoforgeage.

Significant proportion of composite industry is currently produced using prepregs, cured in autoclave which is very expensive and time consuming process. Dry textile preforms in conjunction with liquid molding techniques can lead to significant reductions in material costs, manufacturing costs and cycle times. These dry preforms are typically 2D woven or braided fabrics which also required lay-up and have low interlaminar properties. Through thickness reinforcement provides solution for this problem as it gives better interlaminar properties as well as near net shape performing. Various 3D performing methods are discussed and reviewed in this research where 3D weaving comes out as ideal process to develop near net shape preforms with more efficiency and better material performance. This research highlights the advantages and limitations of conventional 3D weaving processes. A number of approaches for improving the flexibility of 3D weaving process have been presented including changing fiber architecture in different sections of the preform, tapering in the width and thickness directions and finally to change the fiber orientation. It is concluded that multi step and taper fabrics can be produced on conventional weaving by some modifications. Furthermore, a novel 3D weaving machine is designed and developed after reviewing various patents and weaving methods to overcome limitations of conventional weaving machine. Key criterions from limitations of conventional weaving processes are considered and modified such as multiple weft insertion, limited warp stuffer movement, linear take-up to develop 3D weaving machine. In order to achieve isotropic material, two textile technologies are combined to get final requirements. 3D weaving can provide us fibres in 0° and 90° direction with through thickness reinforcement, whereas braiding can satisfy the requirement of bias direction fibres. Near net shape preforms such as taper and multistep are produced and laminated. Preliminary testing is performed on these laminates to evaluate fibre architectures. Further work is required in terms of machine modification which can provide weave design flexibility to explore various multilayer weave architectures. Thorough testing is required to evaluate and define structure performance and effect of fibre damage during weaving process.

Producing composite parts using low-cost processes such as resin transfer moulding (RTM) has received much interest in the aerospace industry. RTM manufactured components require near net shape preforms which closely fit mould cavities. To reduce labour costs associated with composite production, automated preforming processes must be utilized. However, obtaining reproducible high quality preforms is required for manufacturing consistent high quality parts. Stitched multilayer 3D non crimp fabric preforms are well suited for automation and an investigation into quality and performance of components manufactured from these preforms is required. This thesis provides an initial evaluation of quality and mechanical properties of components made from stitched multilayer 3D non crimp fabric preforms using RTM. Similar sized flat plates of varying fibre volume fractions were manufactured to evaluate flexural modulus and strength, short beam shear strength and drop weight impact resistance of the material. Also, integral reinforced panels (IRPs) featuring a reinforcing section joined to a flat plate of varying laminating sequences were manufactured to evaluate debonding strength between sections. Optical microscopy was performed on component samples to determine quality based on void content and was found to be within acceptable limits for production composites. Flexural moduli were found to be comparable with theoretical expected values, however flexural strength was limited by the presence of transverse stitches. Short beam shear strength results showed high consistency between specimens, however were lower than comparable values found in literature. Impact specimens showed consistency among specimens, with greater damage resistance than comparable values found in literature. Determining debonding strength proved difficult as different failure modes were observed between IRPs, however, initial baseline values were acquired.

There is a strong need in forging industry to reduce waste of material, improve quality, and reduce cost of forgings. About 30% of the material is wasted during conventional closed-die forging. Therefore, in order to reduce the cost of forged products and to obtain near-net or net shape parts, new forging methods should be applied. Precision forging concept is a cost-effective way to produce net-shape or near-net shape components. In recent years, there has been an increased interest in the production of gears by the net-shape forging technique. This has specific advantages over the traditional manufacturing processes of cutting gears such as hobbing, turning, and grinding including savings on cost and raw material, increased productivity, and gears with higher dynamic properties than conventionally cut ones. In this study, precision forging of a particular spur gear has been investigated. The precision forging die set has been conceptually designed and modeled in a computer aided design environment. The forging process of particular spur gear has been simulated by using a commercially available finite volume program. After the successful simulation results, the prototype die set and the tube-shaped billets were manufactured. The real-life experiments have been realized by using 1000 tons mechanical forging press available in METUBILTIR Research and Application Center Forging Laboratory. The results have been compared with the computer simulations. After the real-life experiments, it has been observed that the conceptual die design is appropriate and near-net shape spur gears are successfully obtained by the proposed precision forging die set.

No description available.

Laser metal deposition (LMD) offers a unique combination of process flexibility, time savings, and reduced cost in producing titanium alloy components. The current challenge in processing titanium alloys using LMD methods is understanding the complex microstructure evolution as a part is fabricated layer by layer. The current work focuses on the characterization, thermal, and microstructural modeling of multilayered Ti-6Al-4V deposits. A thermal model has been developed using finite difference techniques to predict the thermal history of LMD processes. A microstructure model that predicts the alpha phase fraction and morphology evolution was constructed to quantify the effect of thermal cycling on the as-deposited microstructure evolution. Alpha dissolution and growth are modeled assuming one-dimensional plate dissolution according to a parabolic rate law, and a Johnson-Mehl-Avrami-Kolmorgorov (JMAK) nucleation and growth model, respectively. Alpha morphology (colony-alpha and basketweave-alpha) evolution is tracked using a simplistic approach. Characterization of the deposit has shown that a complex microstructure evolves consisting of a two distinct regions: a transient region of undeveloped microstructure and a characteristic layer that is periodically repeated throughout the deposit. The transient region contains a fine basketweave and colony-alpha morphology. The characteristic layer contains a two phase mixture of alpha+beta, with the alpha phase exhibits regions of colony-alpha (layer band) and basketweave-alpha morphology. The different regions of microstructural contrast in the deposit are associated with thermal cycling. The thermal model results show that a heat affected zone defined by the beta transus extends approximately 3 layers into the deposit. The phase fraction model predicts the greatest variation in microstructural evolution to occur in a layer n after the deposition of layer n+3. The results of the morphology model show that increased amounts of colony-alpha form near the top of a characteristic layer. It follows that a layer band (colony-alpha region) forms as a result of heating a region of material to a peak temperature just below the beta transus, where a large amount of primary-alpha dissolves. Upon cooling, colony-alpha forms intragranularly. The coupled thermal and microstructure models offer a way to quantitatively map microstructure during LMD processing of Ti-6Al-4V. / Ph. D.

Les coûts de revient des alliages de titane limitent leurs applications à des domaines de forte valeur ajoutée. La diminution des coûts de mise en forme des pièces tout en maitrisant les microstructures et les propriétés mécaniques est donc un enjeu important. Les procédés de mise en forme issus de la métallurgie des poudres comme le Spark Plasma Sintering (SPS) peuvent permettre d'atteindre ces objectifs. Les premiers instants du frittage ont été étudiés selon la compacité initiale du corps granulaire. Lorsque cette dernière est faible, les surfaces des cous entre les granules, mises en évidences par microtomographie, sont plus importantes. Ces observations peuvent être expliquées par le fait que les densités de courant au niveau des points de contacts sont plus importantes quand les surfaces de contacts sont plus faibles. De plus, les densités finales très proches malgré les compacités initiales différentes laissent penser que les mécanismes de frittage en action sont différents. Une modélisation Electro-Thermique et Mécanique par éléments finis a permis de décrire de façon très réaliste la densification du TA6V. La loi de densification du matériau a été paramétrée par le biais de campagnes d'essais en fluage menés dans le SPS ainsi que d'essais de compaction du corps granulaire. Des voies d'amélioration du modèle ont également été proposées. Dans la dernière partie de l'ouvrage, un panel des microstructures obtenues par frittage SPS du TA6V ainsi qu'un transfert d'échelle des échantillons modèles cylindriques de petites tailles vers des formes plus complexes et massives ont été étudiés. De plus, les propriétés mécaniques en traction sur pièces près des cotes ont été caractérisées. Les domaines (température et pressions) d'obtention de microstructures denses, homogènes et répétables ont été identifiés. Le transfert d'échelle révèle que la répétabilité du SPS est validée tant en termes de microstructures que de propriétés mécaniques des pièces densifiées. De plus, les propriétés en traction sont au niveau des matériaux forgés, notamment avec des allongements à rupture de près de 13%. / The cost prices of the titanium alloys limit their applications to strong added value fields. The decrease of the pieces shaping costs while mastering microstructures and mechanical properties is an important issue. Shaping processes from powder metallurgy as Spark Plasma Sintering (SPS) can allow to reach these goals. The first moments of the sintering were studied according to the initial compactness of the granular body. When the latter is low, the area of necks between granules, highlighted by microtomography, are bigger. These observations can be explained by the fact that current densities at contact points are higher when the contact areas are lower. Furthermore, the very close final densities in spite of the different initial compactness let think that the mechanisms in action during sintering are different. An electro-thermal and mechanical modelling by finished element allowed to describe in a very realistic way the densification of the TA6V. The densification law of the material was configured by means of creep tests programmes performed dine the SPS chamber as well as of compaction tests of the granular body. Ways of improvement of the model were also proposed. In the last part of the word, a panel of microstructures obtained by SPS of TA6V as well as a scale transfer from the small cylindrical samples towards more massive and complex shapes was studied. Furthermore, the tensile properties of near-net-shape specimens were characterised. Domains (temperature and pressure) of dense, homogeneous and repeatable microstructures obtaining were identified. The scale transfer reveals that the SPS repeatability is both validated in terms of microstructures and mechanical properties of the densified specimens. Furthermore, tensile properties are at the same level as the forged materials, in particular an elongation at break of about 13%.

Macroporous ceramic materials have found widespread technological application ranging from particulate filters in diesel engines, tissue engineering scaffolds, and as support materials in carbon capture processes. This thesis demonstrates how the pore space of macroporous alumina can be manipulated, analysed in three-dimensions (3D) using visualisation techniques, and functionalised with a CO2-adsorbing material. A novel method was developed to produce macroporous alumina materials: by combining sacrificial templating with thermally expandable polymeric microspheres and gel-casting of an alumina suspension. This method offers a versatile production of macroporous ceramics in which the level of porosity and the pore size distribution can easily be altered by varying the amount and type of spheres. The permeability to fluid flow could be regulated by controlling the connectivity of the pore space and the size of the smallest constrictions between the pores. Sacrificial templating with particle-coated expandable spheres significantly increased the fraction of isolated pore clusters and reduced both the sizes and the numbers of connections between neighbouring pores, compared to templating with un-coated spheres. The macroporous alumina materials were characterised with X-ray micro-computed tomography (μ-CT). The 3D data-sets obtained by X-ray μ-CT were used to calculate the spatial variation in porosity, the throat and pore size distributions and to calculate the permeability to fluid flow. The throat and pore size distributions were also able to be accurately quantified in only one extrusion and intrusion cycle with water-based porosimetry; a relatively novel and simple characterisation technique. The pore walls of the macroporous alumina materials were also coated with zeolite films by a colloidal processing technique. The CO2-uptake of the coated alumina materials and of hierarchically porous monoliths of zeolites was evaluated and compared. / As the time of the doctoral defense, the following papers were unpublished and had a status as follows: Paper 2: Submitted. Paper 4: Accepted. Paper 5: Manuscript. Paper 6: Submitted.

L'élaboration de composites à matrice céramique denses et à fibres continues multidirectionnelles par de nouveaux procédés hybrides a été étudiée. Les procédés développés reposent sur le dépôt d'interphases autour des fibres par Infiltration Chimique en phase Vapeur (CVI) puis sur l'introduction de poudres céramiques au sein de préformes fibreuses par infusion de suspensions aqueuses colloïdales concentrées et stables, et enfin sur la consolidation des préformes soit par frittage flash, soit par imprégnation réactive de métaux liquides.La consolidation des composites par frittage flash est très rapide (palier de maintien en température inférieure à 5 minutes) et permet d'obtenir des composites denses. Durant le frittage, la dégradation des fibres de carbone a pu être évitée en adaptant le cycle de pression afin de limiter l'évolution des gaz au sein du système.La densification totale des composites par imprégnation de métaux liquides a été obtenue en contrôlant attentivement les paramètres d'imprégnation afin d'éviter de piéger des espèces gazeuses au sein des préformes fibreuses.Les composites à fibres de carbone consolidés par frittage flash ou par imprégnation réactive de métaux liquide possèdent un comportement mécanique de type élastique endommageable ainsi qu'une contrainte à rupture en flexion voisine de 300 MPa. Ces composites ont montré leur capacité à s'autocicatriser dans des conditions oxydantes. Comparés aux composites à matrice céramiques élaborés par CVI, les composites densifiés par imprégnation de métaux liquide sont eux parfaitement denses et ont un comportement mécanique en traction à température ambiante similaire avec notamment une contrainte à rupture en traction de 220 MPa. / The fabrication of multidirectional continuous carbon fibers reinforced dense self healing Ceramic Matrix Composites by new short time hybrid processes was studied. The processes developed are based, first, on the deposition of fiber interphase and coating by chemical vapor infiltration, next, on the introduction of ceramic powders into the fibrous preform by Slurry Impregnation and, finally, on the densification of the composite by liquid-phase Spark Plasma Sintering (SPS) or by Reactive Melt Infiltration of silicon (RMI).The homogeneous introduction of the ceramic particles into the multidirectional fiber preforms was realized by slurry impregnation from highly concentrated (> 32 %vol.) and well dispersed aqueous colloid suspensions. The densification of the composites by spark plasma sintering was possible with a short (< 5 minutes) dwelling period in temperature. The chemical degradation of the carbon fibers during the fabrication was prevented by adapting the sintering pressure cycle to inhibit gas evolution inside the system. The composites elaborated are dense. The fully densification of the composites by RMI was realised by carefully controlling the impregnation parameters to avoid to entrap some gaseous species inside the fiber preforms. Our carbon fiber reinforced ceramic matrix composites processed by Spark Plasma Sintering or Reactive Melt Infiltration have a damageable mechanical behaviour with a room temperature bending stress at failure around 300 MPa and have shown their ability to self-healing in oxidizing conditions. Compared to the CMC processed by CVI, the composites processed with a final consolidation step by RMI are fully dense and have a similar room temperature tensile test behaviour with an ultimate tensile stress around 220 MPa.