Fibre-Reinforced-Plastics are composite materials composed by thin fibres with high mechanical properties, made to work together with a cohesive plastic matrix. The huge advantages of fibre reinforced plastics over traditional materials are their high specific mechanical properties i.e. high stiffness and strength to weight ratios. This kind of composite materials is the most disruptive innovation in the structural materials field seen in recent years and the areas of potential application are still many. However, there are few aspects which limit their growth: on the one hand the information available about their properties and long term behaviour is still scarce, especially if compared with traditional materials for which there has been developed an extended database through years of use and research. On the other hand, the technologies of production are still not as developed as the ones available to form plastics, metals and other traditional materials. A third aspect is that the new properties presented by these materials e.g. their anisotropy, difficult the design of components. This thesis will provide several case-studies with advancements regarding the three limitations mentioned. In particular, the long term mechanical properties have been studied through an experimental analysis of the impact of seawater on GFRP. Regarding production methods, the pre-impregnated cured in autoclave process was considered: a rapid tooling method to produce moulds will be presented, and a study about the production of thick components. Also, two liquid composite moulding methods will be presented, with a case-study regarding a large component with sandwich structure that was produced with the Vacuum-Assisted-Resin-Infusion method, and a case-study regarding a thick con-rod beam that was produced with the Resin-Transfer-Moulding process. The final case-study will analyse the loads acting during the use of a particular sportive component, made with FRP layers and a sandwich structure, practical design rules will be provided.

The present work aims for investigate the influence of electrospun Nylon 6,6 nanofibrous mat on the behavior of composite laminates. The main idea is that nanofibrous interleaved into particular ply-to-ply interfaces of a laminate can lead to significant improvements of mechanical properties and delamination/damage resistance. Experimental campaigns were performed to investigate how nanofibers affect both the static and dynamic behavior of the laminate in which they are interleaved. Fracture mechanics tests were initially performed on virgin and 8 different configuration of nanomodified specimens. The purposes of this first step of the work are to understand which geometrical parameters of the nanointerleave influence the behavior of the laminate and, to find the optimal architecture of the nanofibrous mat in order to obtain the best reinforcement. In particular, 3 morphological parameters are investigated: nanofibers diameter, nanofibers orientation and thickness of the reinforce. Two different values for each parameter have been used, and it leads to 8 different configurations of nanoreinforce. Acoustic Emission technique is also used to monitor the tests. Once the optimum configuration has been found, attention is focused on the mechanism of reinforce played by the nanofibers during static and dynamic tests. Low velocity impacts and free decay tests are performed to attest the effect of nanointerlayers and the reinforce mechanism during the dynamic loads. Bump tests are performed before and after the impact on virgin and two different nanomodified laminates configurations. The authors focused their attention on: vibrational behavior, low velocity impact response and post-impact vibration behavior of the nano-interleaved laminates with respect to the response of non-nanomodified ones. Experiments attest that nanofibers significantly strength the delamination resistance of the laminates and increase some mechanical properties. It is demonstrated that the nanofibers are capable to continue to carry on the loads even when the matrix around them is broken.

A major weakness of composite materials is that low-velocity impact, introduced accidentally during manufacture, operation or maintenance of the aircraft, may result in delaminations between the plies. Therefore, the first part of this study is focused on mechanics of curved laminates under impact. For this aim, the effect of preloading on impact response of curved composite laminates is considered. By applying the preload, the stress through the thickness and curvature of the laminates increased. The results showed that all impact parameters are varied significantly. For understanding the contribution rate of preloading and pre-stress on the obtained results another test is designed. The interesting phenomenon is that the preloading can decrease the damaged area when the curvature of the both specimens is the same. Finally the effect of curvature type, concave and convex, is investigated under impact loading. In the second part, a new composition of nanofibrous mats are developed to improve the efficiency of curved laminates under impact loading. Therefore, at first some fracture tests are conducted to consider the effect of Nylon 6,6, PCL, and their mixture on mode I and mode II fracture toughness. For this goal, nanofibers are electrospun and interleaved between mid-plane of laminate composite to conduct mode I and mode II tests. The results shows that efficiency of Nylon 6,6 is better than PCL in mode II, while the effect of PCL on fracture toughness of mode I is more. By mixing these nanofibers the shortage of the individual nanofibers is compensated and so the Nylon 6,6/PCL nanofibers could increased mode I and II fracture toughness. Then all these nanofibers are used between all layers of composite layers to investigate their effect on damaged area. The results showed that PCL could decrease the damaged area about 25% and Nylon 6,6 and mixed nanofibers about 50%.

Instrumented indentation testing is now considered one of the most attractive tools for characterizing engineering materials. A large number of materials properties can be investigated. The present dissertation was aimed at developing a new methodology for inferring the material behaviour of metallic materials from their indentation response.

Cellular materials are characterized by a complex interconnected structure of struts or plates and shells which make up the cells edges and faces. Their structure can be advantageously engineered in order to tailor their properties according to the specific application. This aspect makes them particularly attractive for the manufacturing of bone prosthetics since, compared to traditional fully dense implants, although more complex to produce and with less predictable properties, implants with a highly porous structure can be manufactured to match the bone stiffness and at the same time favor bone ingrowth and regeneration. The development of Selective Laser Melting (SLM) made possible to obtain metallic cellular materials with highly complex structures characterized by a wide range of cell morphologies that allow to finely tune the mechanical properties of the implant to the patient needs. Titanium alloys such as Ti-6Al-4V have shown excellent biocompatibility combined with good mechanical properties and have also been successfully used in the manufacturing of lattice structures with minute details via SLM. Nevertheless, there are still several issues to consider. For instance, despite the static mechanical properties of such lattices being addressed by many studies, the fatigue behavior still remains little investigated, even though it is a critical aspect in load-bearing biomedical implants (consider, for example, the periodic nature of human gait in the case of hip implants). In this regard, increasing the fatigue resistance of cellular lattices by finely adjusting the geometry, for instance by adding fillets at the cell-wall joints, is a new interesting opportunity made possible by additive manufacturing technologies. On the other hand, a discrepancy between the as-designed and the as-built geometry in SLM parts is an issue that can be critically important for lattices with pore size and strut thicknesses of a few hundred microns, such as biomedical lattices. Indeed, any geometrical imperfection introduces a degree of uncertainty that can alter the mechanical properties of the as-built lattice. This work represents an attempt in the direction of building a deeper understanding of the effect of the fine geometrical details, such as the fillet radius at the joints and the thickness of the struts, on the elastic constants and on the fatigue resistance of Ti-6Al-4V SLM lattices, with the aim to develop analytical predictive models of the mechanical properties. Moreover, this work also aims at investigating the as-built/as-designed morphological discrepancy in lattices in relation to the their as-designed geometry and its effects on the elastic modulus and the fatigue resistance. In this regard, the purpose is to develop quantitative relationships between the as-designed and the as-built geometry in order to obtain design tools to predict the final morphology of the lattice by taking into account the manufacturing errors. This thesis covers a wide range of topics, therefore, in the interest of a better presentation, the results of the research have been devided into three independent Chapters. Each of them has been provided of an abstract and an Introduction and divided into a Materials and Methods (or Modelling) section, a Results and Discussion section and finally Conclusions and References. Naturally, the chapters are logically connected and coherent with the frame defined by the title of the thesis. Therefore, this thesis is organized into five chapters. In the first Chapter the backrground to the topics discussed in the subsequent chapters is provided and the relevant literature is reviewed, while in the fifth and last Chapter some conclusions are drawn, and future perspectives are discussed. The core of the work is contained in the three central chapters. In Chapter II, analytical models developed to predict the elastic constants and the stress concentration factors (SCF) of 2D lattices with variously arranged square cells and filleted junctions are presented. The effect of stretching and bending actions on the elastic constants of a single cell is identified by devising an analytical model based on classical beam theory and and periodic boundary conditions. Specifically, two spatial arrangements are considered: a honeycomb with regular square cells and a honeycomb with square cells staggered by a prescribed offset of half of the cell wall length. The theoretical beam model is fitted to the results of a 2D Finite Elements (FE) model based on plane elements via an extensive parametric analysis. In this way, semi-analytical formulas are proposed to calculate the stiffness in large domains of the geometric parameters (strut thickness t0 and fillet radius R). A numerical method is also proposed to estimate the SCFs at the cell wall junctions of a 2D regular square cellular lattice. The aim is to obtain a model capable of calculating the values of the SCF as a function of the unit cell geometrical parameters and consequently assess the stress state in the lattice, which is one of the main factors determining fatigue resistance. This was achieved by applying the FE method to the unit cell for wide intervals of t0 and R to calculate the SCF for each couple of the parameters. The values of the SCFs were then fitted with functions. The models developed in this Chapter are then used in the subsequent chapters as a support in the design of 3D regular square lattices and in the interpretation of the mechanical characterization. In Chapter III, the results of the mechanical and morphological characterization of different regular cubic open-cell cellular structures produced via SLM of Ti-6Al-4V alloy, all with the same nominal elastic modulus of 3 GPa that matches that of human trabecular bone, are presented. The fully reversed fatigue strength at 106 cycles and the elastic modulus were measured and an attempt was made to link them to the manufacturing defects (porosity and geometrical inaccuracies). Half of the specimens was subjected to a stress relief thermal treatment while the other half to Hot Isostatic Pressing (HIP), and the effect of the treatments on porosity and on the mechanical properties was assessed. The results of fatigue and quasi-static tests on regular cubic lattices were compared with FE calculations based on the as-designed geometry and on the as-built geometry reconstructed from micro X-ray computed tomography (ÂμCT) scans. It was observed that the fatigue strength and, to a lesser extent, the elastic modulus are correlated with the number and severity of defects and that predictions on the mechanical properties based on the as-designed geometry are not accurate. The fatigue strength seems to be highly dependent on the surface irregularities and on the notches introduced during the manufacturing process. In fully reversed fatigue tests, the high performances of stretching dominated structures compared to bending dominated structures are not found. In fact, with thicker struts, such structures proved to be more resistant, even if bending actions were present. Given the small size of the unit cells (the unit cell size is 1.5 mm and the strut thickness is 0.26 mm) and the limitations in accuracy of the printer, the fillet radii at the junctions were highly irregular and somewhat hard to recognize. In order to investigate the real benefit of filleted junctions on the stress concentration effects at the junctions and to assess the manufacturability of such minute geometrical detail, a new experimental campaign was set up. In Chapter IV, a set of cubic lattice specimens with filleted junctions was designed and produced via SLM. The size of the unit cell is considerably larger than that of the previous specimens, being 8 mm, 6 mm and 4 mm with the rest of the geometrical parameters scaled accordingly. Thus, nine combinations of the geometrical parameters of the unit cell and three orientations with respect to the printing direction are considered. The aim is to investigate the relationship between the as-designed and the as-built geometry and to find the smallest radius which can be accurately reproduced by the printer. Moreover, a compensation strategy of the morphological defects is devised using the mathematical relationships obtained between the as-designed and the as-built strut thickness. This strategy consists in modifying the input CAD to compensate for the deviations introduced by the SLM process.

Il lavoro di ricerca approfondisce la riflessione pedagogica in riferimento alle prassi educative in materia di sostenibilità. L'approccio di approfondimento si impernia sul carattere interdisciplinare del concetto di sviluppo sostenibile. la prima parte del lavoro di ricerca approfondisce L'area sociale in riferimento alla partecipazione della comunità locale nei processi di promozione dello sviluppo sostenibile. La seconda parte del lavoro di ricerca prende in esame una significativa prassi di partecipazione: la progettazione partecipata. / The research provides a pedagogical consideration in relation to the educational techniques concerning sustainability. The approach of a thorough analysis is based on the interdisciplinary nature of the tenable development. The first part of the research gives importance to the social area and the presence of the local community in order to promote the bearable development. The second part takes into consideration an important participation technique: the shared planning.

Il rapido progresso della tecnologia, lo sviluppo di prodotti altamente sofisticati, la forte competizione globale e l’aumento delle aspettative dei clienti hanno messo nuove pressioni sui produttori per garantire la commercializzazione di beni caratterizzati da una qualità sempre crescente. Sono gli stessi clienti che da anni si aspettano di trovare sul mercato prodotti contraddistinti da un livello estremo di affidabilità e sicurezza. Tutti siamo consapevoli della necessità per un prodotto di essere quanto più sicuro ed affidabile possibile; ma, nonostante siano passati oramai 30 anni di studi e ricerche, quando cerchiamo di quantificare ingegneristicamente queste caratteristiche riconducibili genericamente al termine qualità, oppure quando vogliamo provare a calcolare i benefici concreti che l’attenzione a questi fattori quali affidabilità e sicurezza producono su un business, allora le discordanze restano forti. E le discordanze restano evidenti anche quando si tratta di definire quali siano gli “strumenti più idonei” da utilizzare per migliorare l’affidabilità e la sicurezza di un prodotto o processo. Sebbene lo stato dell’arte internazionale proponga un numero significativo di metodologie per il miglioramento della qualità, tutte in continuo perfezionamento, tuttavia molti di questi strumenti della “Total Quality” non sono concretamente applicabili nella maggior parte delle realtà industriale da noi incontrate. La non applicabilità di queste tecniche non riguarda solo la dimensione più limitata delle aziende italiane rispetto a quelle americane e giapponesi dove sono nati e stati sviluppati questi strumenti, oppure alla poca possibilità di effettuare investimenti massicci in R&D, ma è collegata anche alla difficoltà che una azienda italiana avrebbe di sfruttare opportunamente i risultati sui propri territori e propri mercati. Questo lavoro si propone di sviluppare una metodologia semplice e organica per stimare i livelli di affidabilità e di sicurezza raggiunti dai sistemi produttivi e dai prodotti industriali. Si pone inoltre di andare al di là del semplice sviluppo di una metodologia teorica, per quanto rigorosa e completa, ma di applicare in forma integrata alcuni dei suoi strumenti a casi concreti di elevata valenza industriale. Questa metodologia come anche, più in generale, tutti gli strumenti di miglioramento di affidabilità qui presentati, interessano potenzialmente una vasta gamma di campi produttivi, ma si prestano con particolare efficacia in quei settori dove coesistono elevate produzioni e fortissime esigenze qualitative dei prodotti. Di conseguenza, per la validazione ed applicazione ci si è rivolti al settore dell’automotive, che da sempre risulta particolarmente sensibile ai problemi di miglioramento di affidabilità e sicurezza. Questa scelta ha portato a conclusioni la cui validità va al di là di valori puramente tecnici, per toccare aspetti non secondari di “spendibilità” sul mercato dei risultati ed ha investito aziende di primissimo piano sul panorama industriale italiano.

Tribology is known as the science of surfaces in relative motion and involves complex interactions over multiple length and time scales. Therefore, friction, lubrication and wear of materials are intrinsically highly multiphysics and multiscale phenomena. Several modelling and simulation tools have been developed in the last decades, always requiring a trade-off between the available computational power and the accurate replication of the experimental results. Despite nowadays it is possible to model with extreme precision elastic problems at various scales, further eorts are needed for taking into account phenomena like plasticity, adhesion, wear, third-body friction and boundary and solid lubrication. The situation becomes even more challenging if considering non-conventional nano-, as in the case of polymer surfaces and interfaces, or microstructures, as for the hierarchical organisations observed in biological systems. Specically, biological surface structures have been demonstrated to present exceptional tribological properties, for instance in terms of adhesion (e.g., the gecko pad), superhydrophobicity (e.g., the lotus leaf) or fluid-dynamic drag reduction (e.g., the shark skin). This has suggested the study and development of hierarchical and/or bio-inspired structures for applications in tribology. Therefore, by taking inspiration from Nature, we investigate the effect of property gradients on the frictional behaviour of sliding interfaces, considering lateral variations in surface and bulk properties. 3D finite-element simulations are compared with a 2D spring-block model to show how lateral gradients can be used to tune the macroscopic coefficients of friction and control the propagation of detachment fronts. Complex microscale phenomena govern the macroscopic behaviour also of lubricated contacts. An example is represented by solid lubrication or third-body friction, which we study with 3D discreteelement simulations. We show the effects of surface waviness and of the modelling parameters on the macroscopic coefficient of friction. Many other natural systems present complex interfacial interactions and tribological behaviour. Plant roots, for instance, display optimised performance during the frictional penetration of soil, especially thanks to a particular apex morphology. Starting from experimental investigations of different probe geometries, we employ the discrete-element method to compute the expended work during the penetration of a granular packing, conrming the optimal bio-inspired shape. This has allowed to follow also an integrated approach including image acquisition and processing of the actual geometries, 3D printing, experiments and numerical simulations. Finally, another interesting example of advanced biological interface with optimised behaviour is represented by biosensing strucviii tures. We employ fluid-structure interaction numerical simulations for studying the response of spiders' trichobothria, which are among the most sensitive biosensors in Nature. Our results highlight the role of the fluid-dynamic drag on the system performance and allow to determine the optimal hair density observed experimentally. Both the third-body problem and the possibility to tune the frictional properties can be considered as the next grand challenges in tribology, which is going to live a "golden age" in the coming years. We believe the results discussed in this Doctoral Thesis could pave the way towards the design of novel bio-inspired structures with optimal tribological properties, for the future development of smart materials and innovative solutions for sliding interfaces.

Shot peening is a cold-working surface treatment, basically consisting in pelting the surface of the to-be-treated component with a high number of small hard particles blown at relatively high velocity. This causes the plasticization of the surface layer of the substrate, and the generation of a compressive residual stress field beneath the component surface. The surface topology modification can be beneficial for coating adhesion, and the work hardening enhances the fretting resistance of components, but the most commonly appreciated advantage of the process is the increased fatigue resistance in the treated component, due to the compressive residual stress which inhibits the nucleation and propagation of fatigue cracks. In spite of its widespread use, the mechanisms underlying the shot peening process are not completely clear. Many process parameters are involved (material, dimension, velocity of the shots, coverage, substrate mechanical behavior) and their complex mutual interaction affects the success of the process as well as the jeopardizing of any beneficial effect due to the increased surface roughness. Experimental measurements are excessively expensive and time-costly to deal with the wide variability of the process parameters, and their feasibility is not always granted. The effect of shot peening is indeed particularly effective where geometrical details (e.g. notches or grooves) act as stress raisers and where the direct measurement of residual stresses is very difficult. Nonetheless, the knwoledge of the effects of the treatment in this crictical locations would be extremely useful for the quantitative assessment of the effect of shot peening and, ultimately, for the optimization fo the process as well as its complete integration in the design process. The implementation of the finite element method for the simulation of shot peening has been studied since many years. In this thesis the simulation of shot peening is studied, in order to progress towards a simulation approach to be used in the industrial practice. Specifically, the B120 micro shot peening treatment performed with micrometric ceramic beads is studied, which has proven to be very effective of aluminum alloys, such as the aeronautical grade Al7075-T651 alloy considered in this work. The simulation of shot peening on a flat surface is addressed at first. The nominal process parameters are used, to include stochastic variability of the shot dimensions and velocity. A MatLab routine based on the linearization of the impact dent dimension, on the shot dimension and velocity is used to assess the coverage level prior to the simulation and predict the number of shots to full coverage. To best reproduce the hardening phenomena of the substrate material under repeated impacts, the Lemaitre-Chaboche model is tuned on cyclic strain tests. Explicit dynamic finite element simulations are carried out and the statistical nature of the peening treatment is taken into account. The results extracted from the numerical analyses are the final surface roughness and residual stresses, which are compared to the experimentally measured values. A specific novel procedure is devised to account for the effect of surface roughness and radiation penetration in the in-depth residual stress profile. In addition, a static finite element model is devised to assess the concentration effect exerted by the increased surface roughness on an external stress. The simulation of shot peening on an edge is then addressed as a first step towards more complex geometries. Since the true peening conditions are not known in this locations, a synergistic discrete element - finite element method approach is chosen for the correct modelization of the process. A discrete element model of the peening process on a flat surface is used to tune the simulation on the nominal process parameters, i.e. mass flow rate and average shot velocity, and to assess the nozzle translational velocity. Discrete element simulations are used to simulate the process when the nozzle turns around the edge tip. To lower the computing cost, the process is linearized into static-nozzle simulations at different tilting angles. The number of impacting shots and their impact velocity distribution are used to set up the finite element simulations, from which the resulting residual stress field is obtained. In addition to the realistic simulation, two simplified simulation approaches for the practical industrial use are devised. The resulting residual stress fields are compared with the reference residual stress field computed using thermal fields in a finite element simulation, tuned with experimental XRD measurements. The effect of the dimension of the fillet on the edge tip is studied by modifying the finite element model of shot peening on an edge. 3 different fillet radii (up to 40 um) are considered, on the basis of experimental observations. The resulting residual stress field are compared to analyze the effect of the precise geometry of the substrate. Lastly, the simplified simulation approach devised in the case of the edge is used to simulate shot peening on the root of a notch. The resulting residual stress field is again compared to the reconstructed reference one.

The Reverse Engineering (RE) techniques and the Finite Element Modelling (FEM) are widely used tools in many scientific fields. They were firstly developed for the mechanics but in the last times became common for other disciplines. In the thesis these techniques are used for the customization of the wearable products. It is possible to observe that the geometry of whatever wearable product is fundamental for the comfort. In particular, starting from the need of wearable product it is possible to analyse the relative body part and to study the products most appropriate interface geometry to maximize the comfort. The related disciplines are biometrics, biomechanics and anthropometry. In the thesis four different non-contact RE techniques are taken into account: shape from stereo, shape from silhouette, shape from laser and range finding. The first instrument which has been developed is based on the multi stereo vision, focusing the attention to the data filtering and to the generation of the solid model represented by mesh. The second instrument is based on the model generation starting from the silhouette. These two techniques are compared to another laser instrument available on the market. The tolerance on the reconstruction give an error on the total length of the foot of about 2 mm. The tolerance is acceptable for the study of a footwear product anyway it is not sufficient for a scientific research. For this reason a fourth RE system based on range finding is studied. A lot of possible methods were analysed, the multifrequencies, belonging as Fringe Projection Profilometry (FPP) group, has been considered the best compromise between precision, accuracy and elaboration times. An instrument has been developed which in few seconds performs the reconstruction using common, cheap products such as a projector and a camera. The use of the aforementioned RE techniques allowed to adequately reconstruct the geometrical model of the foot, then the deformation of the foot is studied using a Finite Element Analysis (FEA). A model characterized by nearly 200000 elements has been developed. The deformations are congruent with literature data. Anyway, considering the complex validation process of the FE model, caused by the difficulties on measuring the real displacement of the foot under loading condition, a direct matching between the acquired geometry and the final shape of the wearable product has been preferred. A function, capable to analyse the fitting between foot and shoe, through a coefficient called comfort index has been developed.