With the possession of extremely broad unique properties, particulate reinforced aluminum composites are very attractive in diverse applications. Aluminum matrix particulate composites are challenging to work with. A single pressing and sintering process was used to fabricate the reinforced aluminum composites in this study. The key advantage of this method is its comparative low expense. However, abrasive reinforcement powders can lead to shorter tool life. To study the fundamental wear mechanisms during the die compaction process, a new method was developed and combined with experiments to quantify tool wear. Automatic die compaction experiments and tribological experiments are employed in this study. The tribologcial experiments consist of a modified pin-onlat test and a modified loop test. Mass loss of tools was recorded during all the experiments. A new tool wear model was used in this study to investigate effect of different hard phase and different lubricant level on die compaction process.

This study introduces a multiscale model for analyzing nonlinear thermo-viscoelastic responses of particulate composites. A simplified micromechanical model consisting of four sub-cells, i.e., one particle and three matrix sub-cells is formulated to obtain the effective thermal and mechanical properties and time-dependent response of the composites. The particle and matrix constituents are made of isotropic homogeneous viscoelastic bodies undergoing small deformation gradients. Perfect bonds are assumed along the sub-cell⁰́₉s interfaces. The coupling between the thermal and mechanical response is attributed to the dissipation of energy due to the viscoelastic deformation and temperature dependent material parameters in the viscoelastic constitutive model. The micromechanical relations are formulated in terms of incremental average field quantities, i.e., stress, strain, heat flux and temperature gradient, in the sub-cells. The effective mechanical properties and coefficient of thermal expansion are derived by satisfying displacement- and traction continuities at the interfaces during the thermo-viscoelastic deformations. The effective thermal conductivity is formulated by imposing heat flux- and temperature continuities at the subcells⁰́₉ interfaces. The expression of the effective specific heat at a constant stress is also established. A time integration algorithm for simultaneously solving the equations that govern heat conduction and thermoviscoelastic deformations of isotropic materials is developed. The algorithm is then incorporated within each sub-cell of the micromechanical model together with the macroscopic energy equation to determine the effective coupled thermoviscoelastic response of the particulate composite. The numerical formulation is implemented within the ABAQUS, general purpose displacement based FE software, allowing for analyzing coupled heat conduction and deformations of composite structures. Experimental data on the effective thermal properties and time dependent responses of particulate composites available in the literature are used to verify the micromechanical model formulation. The multiscale model capability is also examined by comparing the field variables, i.e., temperature, displacement, stresses and strains, obtained from heterogeneous and homogeneous composite structures, during the transient heat conduction and deformations. Examples of coupled thermoviscoelastic analyses of particulate composites and functionally graded structures are also presented. The present micromechanical modeling approach is found to be computationally efficient and shows good agreement with experiments in predicting the effective thermo-mechanical response of particulate composites and functionally graded materials. Our analyses forecast a better design for creep resistant and less dissipative structures using particulate composites and functionally graded materials.

A unique approach for lightweight multifunctional composites was developed using Fe3O4 nanoparticles and polypyrrole-coated Fe3O4 particles as fillers. Fe3O4 particles are a good candidate for filler in a multifunctional composite system because they can reinforce mechanical properties of a polymer matrix and impart magnetic properties into a composite. Polypyrrole coating on Fe3O4 particles was utilized to incorporate electrical conductivity to the properties of composites. The effects of filler size and filler content were studied on both the mechanical and electromagnetic properties. Fe3O4 nanoparticles improved fracture toughness, but they compromised strength and modulus. Polypyrrole-coated Fe3O4 has potential for multifunctional material applications because the coating allows for concurrent increase in magnetic permeability and electrical conductivity in a composite. The polypyrrole coating also improved the strength of the composite. Fe3O4 nanoparticles were a major part of this work from their synthesis to their application in composites. The surface effect on magnetic properties was analyzed for Fe3O4 nanoparticles, resulting in a more accurate calculation of the magnetically dead layer thickness than previously reported. The results from this work contributed to further understanding of synthesis and characterization of magnetic nanoparticles, fabrication and characterization of nanocomposites, and design and development of lightweight multifunctional materials. Although the properties of the fabricated composites require further improvement, the methodology and approach provide a basis for future work in development of lightweight multifunctional composites.

The master's thesis deals with the determination of macroscopic behavior of a particulate composite with cross-linked polymer matrix under tensile load. The main focus of thesis is estimation of mechanical properties of a composite loaded by tensile loading using numerical methods (especially finite elements method). Investigated composite is composed of matrix in a rubbery state filled by alumina-based particles (Al2O3). Hyperelastic properties of the matrix have been modeled by the Mooney-Rivlin material model. Different compositions of particles, their different shape, orientation and different volume fractions have been considered. For all these characteristics of composite numerical models have been developed. The damage mechanisms of the matrix have also been taken into account. Results of numerical analyses have been compared with experimental data and good agreement between numerical models with damage mechanisms of matrix and experimental data has been found.