This master thesis was carried out at Scania CV AB. The focus for this thesis is the prediction of welding distortions that can cause problems in the manufacturing process of Scania's after-treatment system. The after-treatment system is mainly assembled by sheet metal plates of the ferritic stainless steel EN 1.4509. The plates are welded together. When welding, distortions and residual stresses occur, and they also depend on the sequence in the component was welded together. The distortions and residual stresses can cause tolerance related issues and a lower lifetime for the welded components. Experiments are expensive and therefore it is desirable to simulate the welding process, thereby controlling distortions and optimizing welding sequences. To simulate the welding process and predict the welding distortions a thermo-mechanical FE-model was created for two typical welds found on the after-treatment system. The first scenario was two thin plates welded onto each other in an overlap weld joint and the second scenario was a thin plate welded onto a thick plate in a overlap weld joint. After the FE-model was compared to the experiments. An optimization of the welding sequences was also made on a larger component typically found on the after-treatment system. The FE-model can predict the distortion shape with good accuracy for the T-fillet weld, while the model predicted a more symmetric distortion shape on the overlap weld compared to a more asymmetric shape found on the experiments, but the error is still not very large. The Fe-model can also be used to optimize the welding sequence for bigger components on the after-treatment system within a reasonable time span compared to doing the opimization manually in an experiment. / Detta examensarbete gjordes för Scania CV AB. Fokus for detta examensarbete har varit kvarvarande deformationer efter svetsning som kan skapa problem vid tillverkningen av Scanias avgasefterbehandlingssystem. Avgasefterbehandlingssystemet är till mesta dels konstruerat av stålplåtar av det ferritiska rostfria stålet EN 1.4509, plåtarna är svetsade ihop och då uppstår kvarvarande deformationer. När komponenter svetsas samman uppstår deformationer och restspänningar. Dessa deformationer och restspänningar är också beroende på i vilken sekvens komponenterna har svetsats ihop. Deformationerna och restspänningarna kan skapa problem med toleranser och sänka livslängden för komponenterna som sammanfogats. Experiment är kostsamma och därför är det önskvärt att simulera svetsprocessen, och därav kontrollera deformationerna som uppstår och optimera i vilken sekvens som komponenterna ska svetsas ihop. För att simulera svetsprocessen och prediktera de kvarvarande deformationerna efter svetsning så gjordes termo-mekanisk FE-model för två vanliga svetsscenarion för avgasefterbehandlingssystemet. Det ena scenariot är två tunna plåtar som svetsas ihop i en överlappande position och det andra var en tunn plåt som svetsas på en tjockare plåt. Ett experiment gjordes sedan för båda svetstyperna. Efter att svetstyperna hade jämförts med experimentet så gjordes en optimering av svetssekvensen för en större komponent likt komponenter funna på avgasefterbehandlingssystemet. Den termomekaniska FE-modelen kunde prediktera de kvarnvarande deformationerna och deras form med bra noggrannhet jämfört med experimentet med undantag för en deformationsform på de tunna plåtarna som var mer symmetrisk i FE-modellen jämfört med den asymmetriska formen i experimentet. FE-modellen kunde också användas för att optimera svetssekvensen för den större komponenten inom en rimlig tidsrymd.

Wellen sind essentielle Maschinenelemente zur Übertragung von Kräften und Momenten in Getrieben. Die Forderung der Industrie nach Leistungssteigerung in der Antriebstechnik erfordert höhere Festigkeiten der Wellen. Zur Steigerung der Tragfähigkeit können einerseits höherfeste Werkstoffe und andererseits mechanische Oberflächenverfestigungsverfahren genutzt werden. Das effektive und kostenschonende Verfahren des Festwalzens wird am kritischen Querschnitt des Bauteils zur lokalen Festigkeitssteigerung durchgeführt. Bekannte Auslegungskonzepte, wie die DIN 743 oder auch die FKM Richtlinie berücksichtigen die aus dem Prozess eingebrachten Druckeigenspannungen jedoch nicht oder nur unzureichend. In diesen Auslegungsrichtlinien wird die Tragfähigkeitssteigerung mittels Diagrammen zum Einflussfaktor der Oberflächenverfestigung KV abstrahiert. Es wird davon ausgegangen, dass der Faktor KV die Tragfähigkeitsreserven festgewalzter Bauteile unterschätzt. Der vorliegende Beitrag zeigt auf, wie mittels numerischer Methoden der Einfluss von Druckeigenspannungen auf die Festigkeit von wellenartigen Bauteilen beschrieben werden kann. Dies ermöglicht die Abschätzung und Erschließung vorhandener Tragfähigkeitsreserven. Auf Basis eines mittels röntgenographischer Eigenspannungsmessungen validierten Simulationsmodells für das Festwalzen ungekerbter Bauteile, werden die numerisch ermittelten Eigenspannungen in Festigkeitssimulationen sowohl auf einer Kleinteilprobe als auch einer Bauteilprobe aufgeprägt. Es erfolgt eine elastisch-plastische Simulation des lokalen Beanspruchungszustandes im Bereich dauerfest ertragbarer Lasten entsprechend der Versuchsergebnisse. Ausgewertet werden das Spannungs- und Dehnungsverhalten am kritischen Querschnitt während der Lastwechsel sowie der Eigenspannungsabbau. Abschließend werden die Simulationsergebnisse mit den experimentellen Ergebnissen verglichen. / Shafts are essential machine elements for the transmission of forces and moments in gearboxes. The industry's demand for increased performance in drive technology requires higher fatigue strengths. The effective and cost-saving process of deep rolling is carried out on the critical cross-section of the component to increase fatigue strength locally. However, known design concepts such as DIN 743 or the FKM guideline do not or only insufficiently take into account the residual compressive stresses introduced by the process. In these design guidelines, the increase in fatigue strength is abstracted by means of diagrams on the influence factor of surface condition KV. It is assumed that the factor KV underestimates the fatigue strength reserves of deep rolled components. This article shows how numerical methods can be used to describe the influence of residual compressive stresses on the fatigue strength of shaft-type components. This enables the estimation and utilisation of existing fatigue strength reserves. Based on a simulation model for deep rolling of unnotched components validated by means of X-ray residual stress measurements, the numerically determined residual stresses are applied to a specimen as well as a component in strength simulations. This is followed by an elastic-plastic simulation of the local stress distribution with ultra-high-cycle fatigue loads according to the experimental results. The stress and strain behaviour at the critical cross-section during the load cycles and the residual stress reduction are evaluated. Finally, the simulation results are compared with the experimental results.

As tensões residuais influenciam o comportamento mecânico dos metais e ligas. O campo de tensões pode determinar o desempenho do material. Então, torna-se de grande importância o estudo e a determinação das tensões residuais. O método padrão da difração de raios X para medir tensões s residuais (Método sen2ψ ) apresenta limitações na determinação de tensões caracterizadas por alto gradiente. È por isso que o estudo do gradiente de tensão superficial é um dos mais importantes problemas teóricos e experimentais em mecânica, especialmente no caso da análise de tensões superficiais que surgem após vários tipos de tratamentos superficiais, como: processamento por laser e tecnologia de implantação iônica. A simulação computacional e os métodos numéricos nos dão a possibilidade de resolver os problemas da determinação dos parâmetros do gradiente de tensão. Neste trabalho foi desenvolvida e aplicada a modelação e simulação computacional para o estudo do comportamento de materiais na presença de distribuições de tensão caracterizadas por alto gradiente. Foi aplicada a modelagem para diferentes tipos de tensões com gradiente para metais puros e ligas metálicas. Foi determinada uma forma para usar a modelagem no caso de materiais compósitos e são apresentados resultados para o caso do silumínio, mostrando o comportamento similar deste material compósito aos materiais puros como aço e alumínio. Usando a análise de Fourier, foi determinada a função de distorção nos casos de perfis alargados pela existência de gradiente de tensão. Foi determinada também a relação entre as funções de atenuação e de tensão na função de distorção e são apresentados resultados para diferentes tipos de distribuições de tensão. Ademais, foi desenvolvida uma metodologia para a determinação dos parâmetros do gradiente de tensão usando a simulação computacional das linhas de difração desenvolvida neste trabalho. A metodologia desenvolvida é baseada na simulação dos perfis de difração distorcidos pelo gradiente de tensão superficial e na análise destas distorções. Das metodologias desenvolvidas para a determinação de distribuições de tensões para o caso de gradiente, a que usa transformada de Fourier é matematicamente correta, porem apresenta dificuldades na determinação das funções de gradiente para casos de distribuições muito complexas e na determinação dos relacionamentos das escalas das funções envolvidas no processo de deconvolução. A alta complexidade deste método e os problemas numéricos que acarreta nos levam a propor a metodologia desenvolvida usando as larguras integrais dos perfis de difração para a determinação aproximada da função de distribuição de tensões. Esta metodologia é de simples aplicação e a sua precisão dependerá da quantidade de dados determinados na simulação direta para a obtenção dos gráficos de calibração. / The residual stress influences the mechanical behavior of metals and alloys. The stress field can determine the material performance. Then, become of great importance the study and determination of residual stress field. The standard X-ray diffraction method for residual stress measurement ent ( sen2ψ Method) presents limitations in the strong stress gradient determination. For that reason, the superficial stress gradient determination is one of the most important theoretical and experimental problem in engineering, especially in the analysis of the stress gradients due to surfaces treatments as laser or ionic implantation. The computational simulation and numerical methods give us the possibility of solve this problems. In this work is developed and applied two methods of modeling and simulation for the study of the material behavior with strong stress gradient. Is applied this modeling technique for different stress distribution in pure metals and metallic alloys. Is established a methodology for the composite material cases and is presents the results for the case of siluminium, showing that the behavior is similar to the other metals testing as steel and aluminum. Also, using Fourier analysis is determined the distortion function for the broadened profiles in the presence of stress gradient. In this work is shown the relation between the attenuation and stress distribution functions in the distortion. Is shown, results for several stress distribution functions. Moreover, is developed a methodology for the determination of stress gradient parameters using the computational simulation of the diffraction lines also developed in this work. The methodology is based in the simulation of the profiles broadened by stress gradient and the analysis of these distortions. Of the developed methodologies for the determination of stress distribution functions for the gradient case, the one that uses Fourier analysis is mathematically correct, but presents difficulties in the determination of the gradient functions for cases of complex stress distributions and in the scales determination of the functions involved in the deconvolution process. The high complexity of this method and the numeric problems that it carries leaves as, to propose the use of the developed methodology using the integral breath of the diffraction profiles for the approximate determination of the stress distribution function. The methodology application is simple and its accuracy will depend on the amount of data determined in the direct simulation to obtain the calibration graphics.

As tensões residuais influenciam o comportamento mecânico dos metais e ligas. O campo de tensões pode determinar o desempenho do material. Então, torna-se de grande importância o estudo e a determinação das tensões residuais. O método padrão da difração de raios X para medir tensões s residuais (Método sen2ψ ) apresenta limitações na determinação de tensões caracterizadas por alto gradiente. È por isso que o estudo do gradiente de tensão superficial é um dos mais importantes problemas teóricos e experimentais em mecânica, especialmente no caso da análise de tensões superficiais que surgem após vários tipos de tratamentos superficiais, como: processamento por laser e tecnologia de implantação iônica. A simulação computacional e os métodos numéricos nos dão a possibilidade de resolver os problemas da determinação dos parâmetros do gradiente de tensão. Neste trabalho foi desenvolvida e aplicada a modelação e simulação computacional para o estudo do comportamento de materiais na presença de distribuições de tensão caracterizadas por alto gradiente. Foi aplicada a modelagem para diferentes tipos de tensões com gradiente para metais puros e ligas metálicas. Foi determinada uma forma para usar a modelagem no caso de materiais compósitos e são apresentados resultados para o caso do silumínio, mostrando o comportamento similar deste material compósito aos materiais puros como aço e alumínio. Usando a análise de Fourier, foi determinada a função de distorção nos casos de perfis alargados pela existência de gradiente de tensão. Foi determinada também a relação entre as funções de atenuação e de tensão na função de distorção e são apresentados resultados para diferentes tipos de distribuições de tensão. Ademais, foi desenvolvida uma metodologia para a determinação dos parâmetros do gradiente de tensão usando a simulação computacional das linhas de difração desenvolvida neste trabalho. A metodologia desenvolvida é baseada na simulação dos perfis de difração distorcidos pelo gradiente de tensão superficial e na análise destas distorções. Das metodologias desenvolvidas para a determinação de distribuições de tensões para o caso de gradiente, a que usa transformada de Fourier é matematicamente correta, porem apresenta dificuldades na determinação das funções de gradiente para casos de distribuições muito complexas e na determinação dos relacionamentos das escalas das funções envolvidas no processo de deconvolução. A alta complexidade deste método e os problemas numéricos que acarreta nos levam a propor a metodologia desenvolvida usando as larguras integrais dos perfis de difração para a determinação aproximada da função de distribuição de tensões. Esta metodologia é de simples aplicação e a sua precisão dependerá da quantidade de dados determinados na simulação direta para a obtenção dos gráficos de calibração. / The residual stress influences the mechanical behavior of metals and alloys. The stress field can determine the material performance. Then, become of great importance the study and determination of residual stress field. The standard X-ray diffraction method for residual stress measurement ent ( sen2ψ Method) presents limitations in the strong stress gradient determination. For that reason, the superficial stress gradient determination is one of the most important theoretical and experimental problem in engineering, especially in the analysis of the stress gradients due to surfaces treatments as laser or ionic implantation. The computational simulation and numerical methods give us the possibility of solve this problems. In this work is developed and applied two methods of modeling and simulation for the study of the material behavior with strong stress gradient. Is applied this modeling technique for different stress distribution in pure metals and metallic alloys. Is established a methodology for the composite material cases and is presents the results for the case of siluminium, showing that the behavior is similar to the other metals testing as steel and aluminum. Also, using Fourier analysis is determined the distortion function for the broadened profiles in the presence of stress gradient. In this work is shown the relation between the attenuation and stress distribution functions in the distortion. Is shown, results for several stress distribution functions. Moreover, is developed a methodology for the determination of stress gradient parameters using the computational simulation of the diffraction lines also developed in this work. The methodology is based in the simulation of the profiles broadened by stress gradient and the analysis of these distortions. Of the developed methodologies for the determination of stress distribution functions for the gradient case, the one that uses Fourier analysis is mathematically correct, but presents difficulties in the determination of the gradient functions for cases of complex stress distributions and in the scales determination of the functions involved in the deconvolution process. The high complexity of this method and the numeric problems that it carries leaves as, to propose the use of the developed methodology using the integral breath of the diffraction profiles for the approximate determination of the stress distribution function. The methodology application is simple and its accuracy will depend on the amount of data determined in the direct simulation to obtain the calibration graphics.

Das Ausmaß der Korrosion kann durch den Werkstoff- und Oberflächenzustand gesteuert werden. Wichtige Einflussgrößen sind die Rauheit, Kristallitgröße, Mikroverzerrung, Textur und Eigenspannungen. Am Beispiel von Kaltwalzprozessen werden Abhängigkeiten dieser Größen vom Umformgrad aufgezeigt, die in numerische Simulationen implementierbar sind und somit die Aussagefähigkeit der Berechnungen maßgeblich erhöhen können. Es wird in der vorliegenden Arbeit ein Modell zur qualitativen und quantitativen Erfassung der Zusammenhänge zwischen den Einflussgrößen und der Korrosionsrate vorgeschlagen. Am Beispiel eines unlegierten Stahls (DC04) kann damit die minimal mögliche Korrosionsrate in Schwefelsäure berechnet sowie ein optimierter Ablauf der Prozessroute beim Kaltwalzen abgeleitet werden, um dieses Minimum zu erreichen. Das Modell ist auf weitere Korrosionssysteme übertragbar, was am Beispiel von EN AW-1050/Schwefelsäure aufgezeigt wird. / The extent of corrosion can be controlled by the material and surface state. Important parameters are: roughness, crystallite size, microstrain, texture and residual stresses. Using the example of cold-rolling processes, the dependencies of these parameters on the plastic strain are shown that can be implemented in numerical simulations and allow increasing the information extracted from the calculations significantly. A model is proposed for determining qualitative and quantitative correlations between the corrosion-affecting parameters and the corrosion rate. Using a carbon steel (DC04), the minimal corrosion rate in sulphuric acid can be calculated and an appropriate processing route is suggested. The model can be adopted for other corrosion systems, which is shown for EN AW-1050/sulphuric acid.

L’indentation instrumentée (nanoindentation) est une technique d’analyse des données expérimentales utilisées pour atteindre les propriétés mécaniques de matériaux (dureté H, module de Young E) pour lesquels les techniques classiques sont difficilement applicables voire non envisageables. Ces paramètres mécaniques sont issus de l’exploitation de la seule courbe expérimentale charge-décharge. L’analyse de cette dernière repose sur des nombreux modèles reportés dans la littérature (Oliver et pharr, Field et Swain, Doener et Nix, Loubet et al.) qui considèrent la décharge purement élastique. De nombreuses expériences que nous avons menées, sur divers types de matériaux massifs (aciers inoxydables AISI304, AISI316, AISI430; aciers rapides HSS652; verre de silice SiO2) et revêtus de films minces de TiN et TiO2 ont montré que les propriétés mécaniques (E et H), déduites de la méthode de Oliver et Pharr, dépendent du pourcentage de la courbe de décharge considéré, de la charge appliquée et du rayon de la pointe. De plus, pour un système film-substrat, la technique est en général utilisée pour atteindre les propriétés in-situ du film ou du substrat, alors que la méthode de dépouillement fournit des paramètres composites qu’il faut ensuite déconvoluer. Dans la recherche d’une stratégie simple, permettant d’accéder au module élastique d’un film « dur » pour les applications mécaniques, nous avons fait appel à la simulation numérique. Le code de simulation numérique utilisé, est basé sur la méthode des éléments de frontière. Nos investigations numériques utilisant l’indentation sphérique nous ont permis de mettre en évidence un certain nombre de résultats utiles pour l’analyse des données expérimentales. Nous avons commencé par montrer que aussi bien pour un matériau massif homogène élastoplastique que pour un système film dur – substrat élastoplastique, la relation [delta]=a2/R demeure valable (R étant le rayon de l’indenteur, a le rayon de l’aire projetée de contact). Cela permet de représenter les résultats de l’essai d’indentation sphérique par la courbe pression moyenne F/[pi]a2- déformation a/R . Au début du chargement, la pente cette courbe est proportionnelle au module de Young du film tandis que la pente initiale de la courbe de décharge est proportionnelle au module d’élasticité du substrat. Une relation entre le déplacement de l’indenteur et [delta] , puis une méthode d’analyse d’indentation ont été établies. Enfin, la procédure a été validée numériquement et expérimentalement sur les données issues de l’indentation de divers combinaisons film-substrat (TiN/AISI430, TiN/HSS652 et TiO2/HSS652) avec succès / Depth sensing Indentation (nanoindentation) is an experimental technique increasing retained for the assessment of the mechanical properties of materials (hardness H, Young's modulus E) for which common homogeneous mechanical tests can not be performed or are extremely difficult to perform. The mechanical parameters are obtained from the indentation curve (the plot of the load vs penetration depth during both load and unload). Usually, some methodology reported in the literature (Oliver and pharr, Field and Swain, Doener and Nix, Loubet and al.) are used in order to assess E and H. We have performed a number of experiments on homogeneous materials (stainless steel AISI304, AISI316, AISI430; high-speed steel HSS652; glass SiO2) as well as a film-substrate system (TiN/AISI430, TiN/HSS652, TiO2/HSS652). Applying the Oliver and Pharr methodology, E end H vary with the applied load as well as the percentage of used unload curve retained for the analysis, as reported in the literature. Besides, in the case of the film-substrate system, only composite parameters are obtained instead of the in-situ films properties. In order to establish a simple strategy for the determination of the elastic modulus of a hard coating, we have carried out many simulations using a boundary element based numerical tool. Then a number of useful results have been identified. The well known elastic relation [delta]=a2/R between the relative approach [delta], the projected contact radius a and the punch radius R, remain valid in the plastic range for homogeneous as well as film-substrate specimens. This allows data indentation to be represented in term of mean pressure F/[pi]a2 vs indentation strain a/R . The initial slope of the loading part of the latter curve is proportional to the elastic modulus of the film, while the slope of the initial part of the unloading curve is proportional to the substrate elastic modulus. Our indentation procedure anlysis has been validated experimentally on a number of samples (TiN/AISI430, TiN/HSS652, TiO2/HSS652) after having established a relation between the punch displacement and the relative approach [delta]

Les alliages à base de chrome sont couramment utilisés pour des applications à haute température. Leurs capacités à former une couche d’oxyde thermique protectrice permet de réduire les cinétiques d’oxydation de ces matériaux. En particulier, les alliages Ni-Cr et Fe-Cr forment une couche continue de α-Cr2O3 en surface. La durabilité du système métal/céramique résultant dépend de l’intégrité mécanique de cette couche, et donc des mécanismes d’endommagement susceptibles de se produire lors de l’oxydation ou du refroidissement. L’endommagement est étroitement corrélé au niveau de contraintes résiduelles dans l’oxyde mais aussi à sa microstructure. Dans ces travaux, des alliages Ni-30Cr et Fe-47Cr sont oxydés à l’air à 800, 900 et 1000°C et une approche multi-échelle est proposée pour analyser rigoureusement les contraintes résiduelles aussi bien à des échelles macroscopiques dans le film d’oxyde adhérent qu’à des échelles locales au travers de régions délaminées.A l’échelle macroscopique, les niveaux de contraintes résiduelles sont déterminés grâce à la diffraction des Rayons X conventionnelle et à la spectroscopie Raman. Les taux de délamination des couches d’oxyde et les phénomènes de fluage diffusionnel sont quantifiés en fonction de paramètres métallurgiques conduisant à différents états microstructuraux du système. L’influence de la compétition entre ces deux modes de relaxation de contrainte sur l’endommagement est discutée. A l’échelle microscopique, des cartographies de contraintes résiduelles au travers de différents types de délaminations sont réalisées grâce à la microspectroscopie Raman et à la microdiffraction Synchrotron. En raison de sa résolution latérale, la microspectroscopie Raman est particulièrement appropriée pour analyser les délaminations formées localement. Des observations par microscopie à force atomique ont également été menées afin de décrire la géométrie (dimensions, hauteur) des différents types d’objets délaminés. Ces informations morphologiques complémentaires couplées aux niveaux de contraintes associés permettent une confrontation aux lois de la mécanique du cloquage, et l’extraction de l’adhérence interfaciale. A partir de ces analyses, des schémas et cartes de l’endommagement des couches de chromine sont proposés. / Chromia-former alloy are mainly used for high temperature applications. Their ability to form a protective thermal oxide scale allows reducing oxidation kinetics of the materials. In particular, Ni-Cr and Fe-Cr alloy forms a α-Cr2O3 scale at the surface. Durability of the metal/ceramic system depends on the mechanical integrity of this scale, and also of the scale damage which could appear during oxidation or cooling. These scale damages are closely correlated to the residual stress magnitude in the oxide and to the microstructure. In this work, Ni-30Cr and Fe-47Cr alloys oxidized in air at 800, 900 and 1000°C and a multi-scale approach is proposed to a analyse with accuracy residual stress magnitude both at macroscopic scale in the adherent oxide and at local scale through delaminated area.At macroscopic scale, residual stress magnitudes are determined thanks to conventional X-Ray diffraction and Raman spectroscopy. Delamination rate in the oxide scale and diffusional creep phenomena are quantified in function of metallurgical parameters leadings to different microstructural state of the system. The influence of competition between these two stress release modes on scale damage is discussed. At microscopic scale, residual stress map through different types of delamination are performed thanks to Raman microspectroscopy and Synchrotron microdiffraction. Raman microspectroscopy is particularly appropriated to analyze delamination locally formed, due to its lateral resolution. Observations by atomic force microscopy have been performed to describe the different delamination type (dimension, height). These morphological information and associated residual stresses allows confrontation to buckling mechanic and calculation of the interface toughness. Diagrams and maps concerning the scale damages have been done thanks to these analyses.

Ce travail porte sur l’étude du risque d’amorçage de fissure en fretting/fatigue du contact aubes/disque de soufflante en alliage de titane Ti-6Al-4V d’un turboréacteur civil. De part les vibrations du moteur et le passage du flux d’air, le contact aube/disque est sujet à de microdéplacements: le fretting. Ce problème complexe concerne des zones en contact de faibles dimensions subissant des pressions de contact importantes et des micro-déplacements associées à des structures soumises à des chargements eux-mêmes complexes. Des essais de fretting simple, fretting précontraint et fretting fatigue sont réalisés en vue d’identifier les conditions d’amorçage de fissure pour plusieurs géométries présentant des gradients de contraintes différents. Les résultats expérimentaux mettent en évidence l’effet du gradient de contrainte sur l’amorçage. Ainsi, via des essais présentant une gamme étendue de gradient, il a été confirmé que les gradients de contraintes retardent l’initiation de fissure. Une approche non-locale couplée à un critère de fatigue multiaxiale et identifiée sur une unique condition expérimentale de fretting simple a permis la prédiction de l’ensemble des résultats expérimentaux. Ainsi, une méthodologie prédictive des durées de vie à amorçage a été proposée. Cette approche numérique intègre la multiaxialité du chargement, l’effet du gradient des contraintes, la réponse élastoplastique de l’interface et les limites de fatigue en traction/compression et torsion alternée du matériau. L’interface aube/disque grenaillée du moteur subit une alternance de sollicitations de faibles amplitudes générant l’amorçage de fissure, et de grandes amplitudes favorisant l’usure des zones en contact. Le phénomène de compétition usure/fissure a alors été étudié via les courbes en cloches (durée de vie en fonction de l’amplitude de déplacement) ainsi que l’influence des contraintes résiduelles de grenaillage. Une première conclusion sur l’effet bénéfique de l’usure a pu être apportée dans le cas d’un matériau sans traitement de surface. Si les contraintes résiduelles de grenaillage permettent d’apporter un gain notable sur les durées de vie pour des sollicitations de glissement partiel, à l’inverse, il a été observé que le matériau avec le traitement de surface de grenaillage présente des durées de vie plus faibles pour des sollicitations favorisant l’usure. À travers d’essais inédits avec un dispositif expérimental à trois vérins, le chargement complexe de l’interface aube/disque du moteur a pu être reproduit à l’échelle du laboratoire. Ainsi, la durabilité globale du contact représentatif de l’interface aube/disque de soufflante a été étudiée. Une synergie des sollicitations oligocycliques et polycycliques à l’interface a été constatée provoquant des phénomènes de réorganisation de contraintes résiduelles et l’accélération des cinétiques d’usure. Cette étude a montré l’importance de prendre en compte les sollicitations polycycliques dans le dimensionnement des structures aubes/disque. Ces sollicitations couplent les aspects de fatigue « fissuration » aux phénomènes de cumul de dommage et de cinétique d’usure des interfaces. / This work aims at studying the crack initiation risk of a blade/disk contact under fretting/fatigue loading. The fan stage of a civil engine is studied and the material used is a titanium alloy: Ti-6Al-4V. This complex issue concerns small contacts which are subjected to high contact pressures and micro-displacements. Thus, a complex multiaxial loading occurs on the structure. Fretting, static stressed fretting and fretting fatigue testing are performed in order to quantify the crack nucleation thresholds. In addition, several geometries which present different stress gradient values are used. The experimental results show a stress gradient effect on the crack initiation. Thus, using a wide range of stress gradient, it has been confirmed that stress gradient delays crack nucleation. A multiaxial fatigue criterion is used to determine the equivalent stress field under the contact. Then, a non-local approach, identified thanks to one fretting experimental condition, is employed in order to consider the stress gradient effect. This approach provides the prediction of the whole experimental results. In this way, a predictive method of the initiation fatigue life has been introduced. This numerical approach takes into account the multiaxial loading, the stress gradient effect, the plastic-elastic behavior of the interface and the fatigue strength limits of the material. The blade/disk contacts of the engine are shot-peened. During the flight, interfaces are subjected to low displacement amplitudes leading to crack initiation. On the other hand, during landing and take-off, contacts are submitted to high displacement amplitudes leading to the interface wear. As a consequence, competition between wear kinetic and nucleation one is studied and “bell curves” are plotted (i.e. fatigue life time versus displacement amplitude).Moreover, the effect of the shot-peening residual stresses on fatigue life time is observed. In case of un-treated material, a beneficial impact on the fatigue life time is observed due to wear process. Compressive residual stresses of shot-peening increase the fatigue life when fretting/fatigue on partial slip regime occurs. Nevertheless, a decrease of the fatigue life time is observed when wear process is activated by the gross slip condition. Finally, the complex loading of the engine blade/disk contact has been reproduced in the laboratory. To achieve this, a new testing, using an experimental machine composed of three hydraulic actuators is developed. Thus, the global life time of the representative interface of the fan stage is studied. Oligocyclic (low frequency) and polycyclic (high frequency) solicitations interact themselves and lead, firstly, to a rearrangement of the residual stresses, and secondly, to an increase of the wear kinetics. This research work highlights the interest to consider the polycyclic loadings to design the blade/disk structure. These solicitations reproduce the “cracking” fatigue phenomenon, the cumulative damages and the wear kinetics of the interface.

L’objectif fondamental de cette étude est de montrer la faisabilité de l’élaboration des couches épaisses de zircone non dopée, en contrôlant la microstructure et l’état mécanique, par MOCVD et par Sol-Gel. Dans un premier temps, nous avons essayé d’optimiser les conditions de dépôt de MOCVD, en faisant varier ou en jouant sur les différents paramètres du procédé, conduisant à l’obtention des couches de ZrO2 micrométriques et denses. La stabilité de la phase quadratique de la zircone est conditionnée par la pression partielle en oxygène, la température du substrat ainsi que l’épaisseur du dépôt. La texture cristallographique de type {100} est obtenue pour les dépôts réalisés à une température de substrat T ≤ 850°C et pour de faibles pressions totales. Concernant l’état mécanique des couches de zircone, l’augmentation de l’épaisseur de la couche peut relaxer les contraintes résiduelles de tension au sein du dépôt. Ce phénomène s’accentue au-delà d’une épaisseur critique suite à la création des espacements entre les colonnes de croissance de la couche. Parallèllement, nous avons montré que la qualité des dépôts Sol-Gel est maitrisée par le choix du substrat, l’utilisation de « sols » vieillis, la multiplication du nombre de couches « spin-coating », le mode de dépôt ainsi que la température de recuit. Certaines propriétés caractéristiques du dépôt telles que la cristallisation, la composition de phase et l’adhérence sont aisément contrôlées respectivement par l’âge du sol, la température de recuit et le coefficient de dilatation thermique associé au substrat utilisé. La microstructure (changement de phases, taille des cristallites, texture cristallographique) et les contraintes internes (thermiques et intrinsèques) ont été caractérisées. Le Sol-Gel présente l’avantage de proposer des couches de zircone très peu contraintes par rapport aux films obtenus par le procédé MOCVD. Quel que soit le procédé de dépôt, MOCVD et/ou Sol-Gel, l’élaboration des films de ZrO2 orientés demeure fonction de la température du traitement. La tentative d’élaborer des multicouches de zircone par un couplage MOCVD/Sol-Gel montre la possibilité de sélectionner des paramètres de dépôt propices à la fabrication d’un film présentant un état microstructural et mécanique contrôlé et voulu. / The fundamental purpose of this study is to demonstrate the feasibility to obtain an undoped zirconia thick film, by controlling the microstructure and mechanical state, using MOCVD and Sol-Gel technique. Firstly, we try to optimize the MOCVD deposition conditions, by varying the different process parameters, leading to the production of ZrO2 micrometric and dense films. The stability of the tetragonal zirconia phase depends on the oxygen partial pressure, the substrate temperature and the film thickness. The crystallographic texture of {100} type is obtained for the deposits obtained under a substrate temperature T ≤ 850°C and a low total pressure. Concerning mechanical state of the zirconia films, the thickness increasing can relax the tensile residual stress within the deposit. This phenomenon accents beyond a critical thickness due to the creation of columns spaces during film growth. In the second part, we show that the quality of the Sol-Gel deposition is controlled by substrate origin, use of aged sol, increase of “spin-coating” layers number, deposition mode and annealing temperature. Some deposit characteristics such as crystallization, phase composition and film adhesion are easily controlled by sol aging, annealing temperature and thermal expansion coefficient associated to the used substrate, respectively. The microstructure (phase change, crystalline size, crystallographic texture) and the internal stresses (thermal and residual) were characterized. The Sol-Gel technique has the advantage of providing zirconia films with low stress level compared to the films obtained by MOCVD. Regardless of the deposition process, MOCVD and / or Sol-Gel, the development of ZrO2 oriented films is in function of the treatment temperature. The attempt to get multilayer zirconia by coupling MOCVD/Sol-Gel methods shows the possibility to choose the deposition parameters in order to produce films with controlled and wanted microstructure and mechanical state.

A presente tese tem por objetivo contribuir para o conhecimento do comportamento dependente do tempo das rochas de anidrita e gipso. O maior interesse é fornecer argumentos convincentes sobre os mecanismos físicos responsáveis pelas deformações lentas observadas em algumas escavações subterrâneas realizadas em maciços dessas rochas na Europa, aspecto este que hoje está bastante confuso e escassamente estudado. A hipótese central desta pesquisa é que o comportamento dependente do tempo das rochas de anidrita e gipso deve-se parcial e/ou totalmente às propriedades reológicas (fluência) e não exclusivamente a expansão decorrente da transformação anidrita – gipso como a maioria dos autores sustenta. Este problema será analisado a partir de uma perspectiva experimental através de ensaios específicos. Os ensaios de expansão axial livre em rochas de anidrita permitiram concluir que quando submersas em água destilada, experimentam diminuição de volume por dissolução. Já as amostras de anidrita em contato com solução saturada em 'CA'SO IND.4' mostram uma relação não linear entre deformação axial e o tempo indicando uma taxa de expansão que decresce com o tempo. As taxas de expansão axial variam entre 0,3 e 2,4%/ano. A novidade é que esta expansão se deve à deposição de uma camada contínua formada por neocristais de gipso e não a expansão por hidratação da anidrita como acontece com os argilominerais. O mecanismo de transformação consiste na dissolução da anidrita e posterior precipitação do gipso em condições de sobre-saturação da solução. A transformação mineralógica acontece, na natureza, em condições propícias de temperatura e saturação da solução com íons 'CA POT.2+' e 'SO IND.4'POT.2-'. Propõe-se uma teoria alternativa sobre deformações lentas de maciços sulfáticos baseada na força de cristalização decorrente da deposição de cristais de gipso nas juntas do maciço rochoso. Propõe-se utilizar as formulações termodinâmicas propostas para expansão de concretos por crescimento de etringita e gipso. Os ensaios de fluência uniaxial sob compressão axial constante mostram que ambos os tipos de rochas sulfáticas apresentam comportamentos elasto-visco-plásticos e taxas de deformação axial e lateral da ordem de '10 POT.-12' a '10 POT.-10' 'S POT.-1'. A deflagração da fluência secundária acontece sob tensões de 4 – 6 MPa para gipsitas e de 25 – 40 MPa para anidritas. As análises sobre os possíveis mecanismos de deformação por fluência foram inconsistentes e nenhuma conclusão definitiva foi atingida. Aparentemente a baixas tensões atuariam mecanismos de difusão e dissolução por pressão. A tensões intermediárias dominariam mecanismos de deslocamentos intra e intercristalinos e a altas tensões as rochas deformariam por propagação de microfissuramento. Ensaios de fluência acoplados a sensores de emissão acústica mostram a manifestação de eventos microssísmicos que usualmente se atribuem à propagação de microfraturas mas que podem dever-se a outros mecanismos. Tanto as taxas de expansão axial como de fluência são compatíveis com as taxas de convergência medidas em algumas obras subterrâneas escavadas em maciços sulfáticos, verificando a hipótese central da pesquisa / The purpose of this thesis is to contribute for the knowledge of time-dependent behavior of sulfatic rocks of anhydrite and gypsum. Emphasis is given to provide straightforward arguments about physical mechanisms responsible for creep observed in some underground excavations in those rocks in Europe. Explanation for this phenomena is not clear yet and studies about them are still scarce. The backbone idea behind this research is that the time-dependent behavior of anhydrite and gypsum is totally or at least partially due to rheological properties, and not exclusively due to swelling resulting from the anhydritegypsum transformation. This problem was investigated experimentally with specific tests. Free swelling tests on anhydrite led to the conclusion that when immersed into distilled water, volume decrease due to dissolution is observed. Anhydrite samples in contact with a saturated solution of 'CA'SO IND.4' present a nonlinear relationship between axial strain and time, indicating swelling rate decreasing with time. Axial swelling rates vary between 0,3% and 2,4%/year. The new concept is that this swelling is due to the deposition of a continuous layer of gypsum composed by gypsum neo-crystals, and not due to hydration swelling of anhydrite, a usual with clay minerals. The transformation mechanism consists of anhydrite dissolution and later precipitation of gypsum under over-saturation condition of the solution. The mineralogical transformation takes place in nature under favorable conditions of temperature and solution saturation with 'CA POT.2+' and 'SO IND.4'POT.2-' ions. An alternative theory is proposed about creep of sulfatic rock masses based on crystallization forces resulting from the deposition of gypsum crystals in the rock masses joints. The use of thermodynamic formulations is proposed for concrete swelling due to the growth of ettringite and gypsum. Uniaxial compression creep tests show that both types of sulfatic rocks present elasto-visco-plastic behavior and axial and lateral strain rates of the order of '10 POT.-12' to '10 POT.-10' 'S POT.-1'. Triggering of secondary creep takes places under stresses of the order of 4 – 6 MPa for gypsum and 25 – 40 MPa for anhydrite. The analyses about the possible creep mechanisms were not consistent and no definite conclusion has been reached get. Apparently under low stresses diffusion and pressure dissolution mechanism dominate. Under intermediate stresses, intra- and inter crystalline displacement mechanisms seem to dominate, and under high stresses rock deform due to microcrack propagation. Creep tests monitored with acoustic emission devices show the occurrence of microseismic events attributed to microcrack propagation. Both axial swelling and creep rock are compatible with convergence rocks measured in some underground works excavated in sulfatic rock masses, following the central idea of this thesis