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Residual stress measurement methods have commonly been used to characterize states of stress in various elastic isotropic materials. In order to investigate the effects of elastic anisotropy on residual stress measurements, commercially pure grade 2 titanium (CP Ti Gr 2) was selected to study a strong texture, or preferred grain orientation. Warm rolled and air-cooled CP titanium is well known to have a texture from the factory. This texture and resulting elastic anisotropy were confirmed using two material characterization methods, resonant ultrasound spectroscopy (RUS) and electron backscatter diffraction (EBSD). The texture was further developed using a rolling mill to cold roll the titanium. A vacuum furnace set to a temperature of 550 C for one hour was used to stress relieve the titanium without reducing the texture. RUS and EBSD methods were used again to confirm the texture achieved by cold rolling. Well-characterized residual stresses were introduced with a shrink-fit ring and plug. The residual stress hole drilling method was used to characterize stresses in the rolling and transverse directions of the ring and plug assemblies. Stress profiles from hole drilling indicated some possible elastic anisotropic effects in two assemblies and are presented. However, more assemblies are needed to confirm the results. A stress determination technique with higher sensitivity may be necessary to substantiate assembly stress profile results.

The influence of silane treated amorphous fumed silica fillers on properties of the cured epoxy was examined in the first part of the study. Silica particles were treated with 3- aminopropyldiethoxymethylsilane (APDS) and 3-aminopropyltriethoxysilane (APTS) coupling agents. The filler and coupling agents decreased the mobility of the polymer chains in the vicinity of the filler leading to an increase in the activation energy for the glass transition and an increase in cooperativity. Fumed silica did not significantly affect moisture diffusion properties. Next, a linear dilatometer was used to investigate the effects of cure conditions, mold types, and the presence of filler in the model epoxy. These studies revealed that there was substantial shrinkage in the cured epoxy on heating it through its glass transition region. The shrinkage was determined to be the result of stress in the epoxy generated during cure and could be minimized by curing at lower temperatures, followed by a postcuring heat treatment. Additional free volume in the sample increased the magnitude of the shrinkage by allowing increased stress release through increased network mobility. Decreasing the polymer mobility by adding fillers decreased the observed shrinkage. The influence of the model epoxy crosslink density was examined by varying the content of 1,4-butanediol in the model system. Addition of 1,4-butanediol led to a decrease in the modulus and glass transition temperature, which resulted in a reduction in residual stress and subsequent shrinkage. Moisture uptake increased with the addition of 1,4-butanediol due to an increase in the free volume of the epoxy. However, even with greater moisture uptake, the addition of 1,4-butanediol to the epoxy increased its adhesion to quartz by promoting lower residual stress and increased energy dissipation. These results indicate that bulk diffusion of water is not the controlling factor in adhesive degradation in this system. / Ph. D.

Biomineral composites, consisting of intercrystalline organics and biogenic minerals, have evolved unique structural designs to fulfill mechanical and other biological functionalities. Aside from the intricate architectures at the composite level and 3D assemblies of the biomineral building blocks, the individual mineral blocks enclose intracrystalline structural features that contribute to the strengthening and toughening at the intrinsic material level. Therefore, the design strategies of biomineralized composites can be categorized into two structural levels, the individual building block level and the composite level, respectively. This dissertation aims at revealing the material design strategies at both levels for the bioinspired designs of advanced structural ceramics. At the building block level, there is a lack of comparative quantification of the mechanical properties between geological and biogenic minerals. Correspondingly, I first benchmark the mechanical property difference between biogenic and geological calcite through nanoindentation techniques. The selected biogenic calcite includes Atrina rigida prisms and Placuna placenta laths, corresponding to calcite {0001}, and {101 ̅8} planes. The natural cleavage plane {101 ̅4} of geological calcite was added to the comparative study. Under indentation load, geological calcite deforms plastically via twinning and slips under low loads, and shifts to cleavage fracture under high loads. In comparison, the P. placenta composites, composed of micro-sized single-crystal laths and extensive intercrystalline organic interfaces, exhibit better crack resistance. In contrast, the single-crystal A. rigida prisms show brittle fracture with no obvious plastic deformation. Secondly, how the internal microstructures and loading types affect the mechanical properties of individual building blocks is investigated. The prismatic building blocks are obtained from the bivalves A. rigida and Sinanodonta woodiana, where the former consists of single-crystal calcite and the latter consists of polycrystalline aragonite. The comparative investigation under different loading conditions is conducted through micro-bending and nanoindentation. The continuous mineral matrix in A. rigida prisms leads to comparable modulus under tensile and compressive loadings in the elastic regime, while the high-density intracrystalline nanoinclusions contribute to the conchoidal fracture behaviors (instead of brittle cleavage). In comparison, the interlocking grain boundaries in S. woodiana prisms correlate with easier tensile deformation (smaller tensile modulus) than compression, as well as the intergranular fracture morphologies. The third topic in the biomineral-level investigation focuses on how biomineral utilizes residual stress at the macroscopic scale. The selected model system is the spine from the sea urchin Heterocentrotus mamillatus, which has a bicontinuous porous structure and mesocrystalline texture. It is confirmed that the spine has a macroscopic stress field with residual tension in the central medulla and compression in the radiating layers. The multimodal characterizations on the spine conclude that the structural origins are not associated with the gradient distribution of the intracrystalline defects, including Mg substitution in the calcite matrix, intracrystalline organics, and amorphous calcium carbonates (ACC). It is hypothesized that the residual stress is generated due to the volume expansion during ACC crystallization at the compacted growth front. At the composite level, even though enhanced crack resistance is expected in biomineralized composites due to their hierarchical structures, the correlation between their 3D composite structures and damage/crack evolution is quite limited in the literature. I developed in-situ testing devices integrated with synchrotron-based X-ray tomography to capture the crack propagation in the materials, including the four-point bending and compression/indentation configurations. Two representative models are chosen to demonstrate the deformation of biomineralized composites under bending and compression, respectively, including the calcium carbonate-based gastropod shell (Melo diadema) and the hydroxyapatite-based fish teeth (Pogonias cromis). Also, the two composites are designed to achieve different functional requirements, i.e., enhanced fracture toughness vs. wear resistance. The comprehensive characterizations of these two composites revealed how biological structural composites are designed accordingly to their functional needs. For the crossed-lamellar M. diadema shell, directional dependence of the shell property was revealed, where the transversal direction (perpendicular to the growth line) represents both the stronger and tougher direction, but the longitudinal direction is more resistant to notches and defects. For the P. cromis teeth, the enhanced wear resistance of the near-surface enameloid originates from the intricate designs at the microscale, with c-axes of hydroxyapatite crystals and micro-sized enameloid rods coaligned with biting direction and F and Zn doping. In addition, the fracture morphologies of the fish teeth correlate with the microstructures; the enameloid exhibits corrugated fracture paths due to the interwoven fibrous building blocks, and the dentin exhibits clean planar fracture surfaces. / Doctor of Philosophy / Ceramic materials have wide applications in daily life and advanced technologies, and examples range from kitchenware (e.g., cups and plates) to spacecraft (e.g., thermal coating). These materials have indispensable applications due to their advantages of high strength and hardness, high heat and corrosion resistance, lightweight, chemical inertness, etc. Yet, intrinsic brittleness usually limits their applications. Typical ways to enhance the toughness of ceramics involve microstructure design (by refining the sizes and shapes of grains) and transformation toughening (phase transition) at the individual grain level, composite reinforcement (or ceramic matrix composites) at the composite level, and introducing residual stress to impede crack initiation and propagation. The engineering methods usually involve high energy input, chemical treatment, and usually significant waste and non-ecofriendly emissions. Therefore, learning the design strategies from biological ceramic solids constructed by organisms wound provide valuable insights into enhancing the performance of ceramics while reducing the harmful impact on the environment. In this dissertation, I investigated the mechanical design strategies from natural 3D biomineralized composites from two structural levels, i.e., building-block and composite levels, analogous to individual grains and composite reinforcement in engineering ceramics. For the building-block level research, the model systems include bivalve shells Atrina rigida, Placuna placenta, and Sinanodonta woodiana. The three bivalve shells contain different building blocks with intrinsic microstructures, corresponding to monolithic prisms with controlled nanoinclusions, diamond-shaped thin laths, and polycrystalline prisms with interlocking grains, respectively, presenting different structural designs of individual grains in ceramic materials. The sea urchin Heterocentrotus mamillatus spine represents a natural porous material with compressive residual stress on the surface, and the investigation of the structural origins aims to provide insights into the cost-effective synthesis of stressed ceramics with residual stress for engineering applications. In addition, the composite-level studies focus on the composite structures of the crossed-lamellar shell Melo diadema and the fish teeth from Pogonias cromis. These two model systems correspond to natural ceramic matrix composites with nano-scale fibrous building blocks arranged in 3D specialized for enhanced crack resistance and wear resistance, respectively. The comprehensive investigation of the deformation behaviors and mechanisms allows for a better understanding of the intricate strategies specialized for different functional requirements, which apply to bio-inspired designs in ceramic composites.

This research explores the nearly untapped research area of the analysis of fracture mechanics in residual stress zones. This type of research has become more prevalent in the field in recent years due to the increase in prominence of residual stress producing processes. Such processes include additive manufacturing of metals and installation procedures that lead to loads outside the anticipated standard operating load envelope. Abaqus was used to generate models that iteratively advanced toward solving this problem using the compact tensile specimen geometry. The first model developed in this study is a two-dimensional fracture model which then led to the development of an improved three-dimensional fracture model. Both models used linear elastic fracture mechanics to determine the stress intensity factor (K) value. These two models were verified using closed-form equations from linear elastic fracture mechanics. The results of these two models validate the modeling techniques used for future model iterations. The final objective of this research is to develop an elastic-plastic fracture mechanics model. The first step in the development of an elastic-plastic fracture model is a three-dimensional quasi-static model that creates the global macroscale displacement field for the entire specimen geometry. The global model was then used to create a fracture submodel. The submodel utilized the displacement field to reduce the model volume, which allowed a higher mesh density to be applied to the part. The higher mesh density allowed more elements to be allocated to accurately represent the model behavior in the area local to the singularity. The techniques used to create this model were validated either by the linear elastic models or by supplementary dog bone prototype models. The prototype models were run to test model results, such as plastic stress-strain behavior, that were unable to be tested by just the linear elastic models. The elastic-plastic fracture mechanics global quasi-static model was verified using the plastic zone estimate and the fracture submodel resulted in a J-integral value. The two-dimensional linear elastic model was validated within 6% and the three-dimensional linear elastic model was validated within 0.57% of the closed-form solution for linear elastic fracture mechanics. These results validated the modeling techniques. The elastic-plastic fracture mechanics quasi-static global model formed a residual stress zone using a Load-Unload-Reload load sequence. The quasi-static global model had a plastic zone with only a 0.02-inch variation from the analytical estimate of the plastic zone diameter. The quasi-static global model was also verified to exceed the limits of linear elastic fracture mechanics due to the size of the plastic zone in relation to the size of the compact specimen geometry. The difference between the three-dimensional linear elastic fracture model J-integral and the elastic-plastic fracture submodel initial loading J-integral was 3.75%. The J-integral for the reload step was 18% larger than the J-integral for the initial loading step in the elastic-plastic fracture submodel. / Master of Science / Additive manufacturing, sometimes referred to as 3-D printing, has become an area of rapid innovation. Additive manufacturing methods have many benefits such as the ability to produce complex geometries with a single process and a reduction in the amount of waste material. However, a problem with these processes is that very few methods have been created to analyze the initial part stresses caused by the processes used to additive manufacture. Finite element methods are computer-based analyses that can determine the behavior of parts based off prescribed properties, shape, and loading conditions. This research utilizes a standard fracture determination shape to leverage finite element methods. The models determine when a crack will form in a part that has process stresses from additive manufacturing. The model for crack initiation was first developed in two dimensions, neglecting the thickness of the part, using a basic material property definition. The same basic material property definition was next used to develop a crack initiation model in three dimensions. Then a more advanced material property definition was used to capture the impact of additive manufacturing on material properties. This material property definition was first used to establish the part properties as it relates to part weakening due to additive manufacturing. A higher accuracy model of just the crack development area was produced to determine the crack initiation properties of the additive manufactured part. Methods previously confirmed by testing were used to validate the models produced in this research. The models demonstrated that under the same loading parts with initial processes stresses were closer to fracture than parts without initial stresses.

An analytic treatment of stresses and temperatures generated during grinding is presented from an elasticity approach. A two-dimensional heat conduction model employs an energy partition scheme in the grinding zone to produce realistic temperature profiles. By using the basic equations of thermoelasticity, the temperature profiles yield thermal stresses. An extension of the Hertzian contact theory yields mechanical stresses, which are then superimposed on the thermal stresses. Approximate plasticity corrections are used to approximate the deformation as the grinding wheel passes over the workpiece. Subsurface results are qualitatively consistent with those found experimentally. However, they still do not agree with near-surface experimental results. Possible explanations and areas of further research are discussed. / Master of Science

Functionally graded structures have material properties that continuously vary in one or more directions. Examples include human teeth, seashells, bamboo stems and human organs, where the varying volume fraction of fibers and their orientations optimize functionality. Deformations of such structures typically involve bending, stretching, and shearing. An everyday example of shearing deformation is the twisting of wet fabrics to extract water. In this study, we analytically examine the large deformations of functionally graded Mooney-Rivlin circular cylinders, focusing on how radial grading of material moduli can be beneficially utilized. We investigate the finite deformations caused by pressures applied to the bounding surfaces and axial loads or twisting moments on the end faces. We also simulate residual stresses in a hollow cylinder either by inverting it inside out or by closing a longitudinal wedge opening parallel to the cylinder axis through axisymmetric deformation before other loads are applied. It is observed that the maximum shear stress in an initially stress-free Mooney-Rivlin cylinder can occur at an interior point. In the absence of axial forces on the end faces, the cylinder elongates when twisted, with the degree of elongation depending on the grading of the material moduli. These findings should aid numerical analysts in verifying their algorithms for simulating large deformations of rubber-like materials modeled by the Mooney-Rivlin relation. / Master of Science / Functionally graded materials (FGMs) are composites whose properties vary in one or more directions to exploit the functionality of the individual components. An example would be a sheet of material that is fully metallic on one side and fully ceramic on the other, with properties changing gradually through the thickness. The Mooney-Rivlin model is used to capture the stress-strain response of rubber-like materials. Therefore, functionally graded Mooney-Rivlin cylinders are rubber-like composite cylinders whose properties change throughout their thickness. Functionally graded cylinders have a wide array of applications, including in pressure vessels, vibration damping systems and tires. Therefore, having a thorough understanding of the stresses induced in these cylinders when subjected to loads is essential for safe and reliable designs. This research aims to investigate the effects of material inhomogeneity on the stresses induced in functionally graded cylinders subjected to torsion, radial expansion, eversion, and various combinations of these. Furthermore, realizing that stresses induced during the fabrication process cannot be easily quantified, we study a problem in which these induced stresses can be determined and analyze their effect on subsequent deformations of the cylinder when subjected to torsion and radial expansion. To achieve this aim, we use a member of Ericksen's third family of universal deformations, which mathematically describes torsion, inflation, and eversion, along with the Mooney-Rivlin model to determine the stress state resulting from deformation. The results show that for cylinders of the same geometry in the stress-free undeformed state subjected to identical surface tractions, material inhomogeneities greatly influence the stresses in the cylinder. It was also found that the magnitude of the normal and shear stresses, axial stretch, and the geometry of the cylinder after deformation depend on the type of deformation and functional grading. Additionally, the results indicate that the normal stresses induced in an initially stressed cylinder are much greater than those in a cylinder that is initially stress-free when subjected to the same boundary conditions.

O Jateamento com granalha (shot peening, em inglês) é um processo de fabricação amplamente utilizado em indústrias mecânicas, automotivas, navais, aeronáuticas e outras indústrias metalúrgicas. O objetivo principal é induzir tensões residuais de compressão para melhorar a vida à fadiga das peças e estruturas. A modelagem e simulação do processo são muito difíceis, pois envolvem a consideração de muitos e complexos aspectos. Este trabalho propõe um método de modelagem tridimensional utilizando o método dos elementos finitos para a simulação numérica desse processo assim como a sua influência na propagação de trinca, considerando efeitos pouco estudados, como o amolecimento do material devido ao aumento da temperatura na peça durante os impactos, ao comportamento elasto-plástico das granalhas e a rugosidade da peça tratada nos parâmetros da trinca. A modelagem proposta para simular o processo de jateamento com granalhas inclui: (i) análise dinâmica explícita, (ii) modelagem tridimensional, (iii) cálculo da velocidade real das granalhas, (iv) modelo de contato com coeficientes de atrito estático e dinâmico entre as áreas em contato, (v) o modelo constitutivo de Johnson-Cook para o comportamento do material alvo, (vi) um comportamento elasto-plástico multilinear para as granalhas, (vii) a consideração da cobertura real de uma área dada da superfície jateada, (viii) a consideração do aumento da temperatura no material durante o processo e (ix) o relaxamento de tensões residuais devido a este aumento de temperatura. As simulações numérico-computacionais para investigar a influência do processo em fenômenos, tais como fadiga e propagação de trinca, necessitou uma nova abordagem para a incorporação das tensões residuais num modelo de elementos finitos. Além disso, foram realizados vários ensaios quase-estáticos e dinâmicos para a determinação dos parâmetros do modelo constitutivo de Johnson-Cook para o aço AISI 5160. Para a avaliação das metodologias propostas, as tensões residuais foram introduzidas e avaliadas em uma mola parabólica automotiva, sendo que as tensões residuais foram avaliadas através da técnica de difração de raios-X, a intensidade e a cobertura do processo de jateamento com granalha na mola foram avaliadas com Lupa e rugosímetro. Também, dados experimentais de ensaios de fadiga relatados na literatura, realizados em corpos de prova tipo CT foram utilizados. A modelagem numérica do processo de jateamento com granalha desenvolvida neste trabalho consegue prever com sucesso os perfis das tensões residuais, com valores bem próximos aos obtidos experimentalmente. A investigação numérica do efeito do processo na vida à fadiga e fratura das peças comprovou a sua influência nos parâmetros de propagação de trinca nas regiões afetadas pelo processo, ocasionando um amplo aumento da vida à fadiga, e confirmou o relaxamento das tensões residuais devido aos ciclos de carregamento conforme as observações experimentais na literatura. / Shot peening is a manufacturing process widely used in the mechanical, automotive, marine, aeronautical and other metallurgical industries. The main purpose is to induce residual compression stresses to improve fatigue life. The modeling and simulation of the process are very difficult as they involve the consideration of many and complex aspects. This work proposes a three-dimensional modelling method using the finite element method for the numerical simulation of this process as well as its influence on crack propagation, considering little studied effects such as softening of the material due to the increase in temperature in the part during impacts , the elastic-plastic behavior of the shot and the roughness of the treated part in the crack parameters. The proposed modelling approach to simulate the shot peening process includes: (i) explicit dynamic analysis, (ii) three-dimensional modeling, (iii) calculation of the real velocity of the shot, (iv) contact model with static and dynamic friction coefficients between the contact areas, (v) the Johnson-Cook constitutive model for target material behavior, (vi) a multilinear elasto-plastic behavior for the shot, (vii) consideration of real coverage in a given area of the peened surface, (viii) consideration of temperature increase in the material during the process and (ix) relaxation of residual stresses due to this rise in temperature. Numerical-computational simulations to investigate the influence of the shot peening process on phenomena, such as fatigue and crack propagation, required a new approach for the incorporation of residual stress in a finite element model. In addition, several quasi-static and dynamic tests were carried out to determine the parameters of the constitutive Johnson-Cook model for AISI 5160 steel. To assess the proposed methodologies, the residual stresses were introduced and evaluated in an automotive parabolic spring, with the residual stresses being evaluated by the X-ray diffraction technique, the intensity and coverage of the shot peening process for the spring were evaluated with magnifying glass and roughness gauge. Also, fatigue tests available in the literature, carried out on types of CT specimens, were used. The numerical modeling of the shot peening process developed in this work can successfully predict the residual stress profiles, with values close to those obtained experimentally. The numerical investigation of the effect of the process in the fatigue life and fracture of the pieces proved its influence in the parameters of crack propagation in the regions affected by the process, causing a wide increase of the fatigue life, and confirmed the relaxation of the residual stresses due to the cycles loading according to experimental observations in the literature.

Nowadays there is a strong demand for lighter vehicles in order to increase the pay load. Through this the specific fuel consumption is decreased, the amount of greenhouse gases is lowered and the transport economy improved. One possibility to optimize the weight is to make the components from high strength steels and join them by welding. Welding is the main joining method for fabrication of a large proportion of all engineering structures. Many components experience fatigue loading during all or part of their life time and welded connections are often the prime location of fatigue failure.Fatigue fracture in welded structures often initiates at the weld toe as aconsequence of large residual stresses and changes in geometry acting as stress concentrators. The objective of this research is to increase the understanding of the factors that control fatigue life in welded components made from very high strength steels with a yield strength of more than 800 MPa. In particular the influences of the local weld toe geometry (weld toe radius and angle) and residual stress on fatigue life have been studied. Residual stresses have been varied by welding with conventional as well as Low Transformation Temperature (LTT) filler materials. The three non-destructive techniques Weld Impression Analysis (WIA), Laser Scanning Profiling (LSP) and Structured Light Projection (SLP) have been applied to evaluate the weld toe geometry.Results suggest that all three methods could be used successfully to measure the weld toe radius and angle, but the obtained data are dependent on the evaluation procedure. WIA seems to be a suitable and economical choice when the aim is just finding the radius. However, SLP is a good method to fast obtain a threedimensional image of the weld profile, which also makes it more suitable for quality control in production. It was also found that the use of LTTconsumables increased fatigue life and that residual stress has a relatively larger influence than the weld toe geometry on fatigue strength of welded parts.