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No description available.

No description available.

This investigation concerns the design, build, and testing of a new class of skin friction sensor capable of performing favorably in high-speed, high-enthalpy flow conditions, such as that found in atmospheric re-entry vehicles, scramjets, jet engines, material testing, and industrial processes. Fully understanding and optimizing these complex flows requires an understanding of aerodynamic properties at high enthalpies, which, in turn, requires numerical and analytical modeling as well as reliable diagnostic instrumentation. Skin friction is a key quantity in assessing the overall flight and engine performance, and also plays an important role in identifying and correcting problem areas. The sensor design is founded on a direct-measuring, cantilever arrangement. The design incorporates two fundamental types of materials in regards to thermal conductivity and voltage resistivity properties. The non-conducting material distinction greatly deters the effect of heat soak and prevents EMI transmission throughout the sensor. Four custom fabricated metal-foil strain gauges are arranged in a Wheatstone bridge configuration to increase sensitivity and to provide further compensation for sensitivity effects. The sensor is actively cooled via a copper water channel to minimize the temperature gradient across the electronic systems. The design offers a unique immunity to many of the interfering influences found in complex, high-speed, high-enthalpy flows that would otherwise overshadow the desired wall shear measurement. The need to develop an encompassing design methodology was recognized and became a principal focus of this research effort. The sensor design was developed through a refined, multi-disciplinary approach. Concepts were matured through an extensive and iterative program of evolving key performance parameters. Extensive use of finite element analysis (FEA) was critical to the design and analysis of the sensor. A software package was developed to utilize the powerful advantage of FEA methods and optimization techniques over the traditional trial and error methods. Each sensor endured a thorough series of calibrations designed to systematically evaluate individual aspects of its functionality in static, dynamic, pressure, and thermal responses. Bench-test facilities at Virginia Tech (VT) and Air Force Research Laboratory (AFRL) further characterized the design vibrational effects and electromagnetic interference countermeasure effectiveness. Through iterations of past designs, sources of error have been identified, controlled, and minimized. The total uncertainty of the skin friction sensor measurement capability was determined to be ±8.7% at 95% confidence and remained fairly independent of each test facility. A rigorous, multi-step approach was developed to systematically test the skin friction sensor in various facilities, where flow enthalpy and run duration were progressively increased. Initial validation testing was conducted at the VT Hypersonic Tunnel. Testing at AFRL was first performed in the RC-19 facility under high-temperature, mixing flow conditions. Final testing was conducted under simulated scramjet flight conditions in the AFRL RC-18 facility. Performance of the skin friction sensors was thoroughly analyzed across all three facilities. The flow stagnation enthalpies upward of 1053 kJ/kg (453 Btu/lbm) were tested. A nominal Mach 2.0 to 3.0 flow speed range was studied and stagnation pressure ranged from 172 to 995 kPa (25 to 144 psia). Wall shear was measured between 94 and 750 Pa (1.96 and 15.7 psf). Multiple entries were conducted at each condition with good repeatability at ±5% variation. The sensor was also able to clearly indicate the transient flow conditions of a full scramjet combustion operability cycle to include shock train movement and backflow along the isolator wall. The measured experimental wall shear data demonstrated good agreement with simple, flat-plate analytical estimations and historic data (where available). Numerical CFD predictions of the scramjet flow path gave favorable results for steady cold and hot flow conditions, but had to be refined to handle the various fueling injection schemes with burning in the downstream combustor and surface roughness models. In comparing CFD wall shear predictions to the experimental measurements, in a few cases, the sensor measurement was adversely affected by shock and complex flow interaction. This made comparisons difficult for these cases. The sensor maintained full functionality under sustained high-enthalpy conditions. No degradation in performance was noted over the course of the tests. This dissertation research and development program has proven successful in advancing the development of a skin friction sensor for applications in high-speed, high-enthalpy flows. The sensor was systematically tested in relevant, high-fidelity laboratory environments to demonstrate its technology readiness and to successfully achieve a technology readiness level (TRL) 6 milestone. The instrumentation technology is currently being transitioned from laboratory development to the end users in the hypersonic test community. / Ph. D.

The aim of this project was to, based on a given idea, develop and evaluate a method for measuring residual stress in thin PVD coatings. AlCrN was deposited, by PVD, on thin circular samples of stainless steel foil and the radius of the emerged curvature was measured using an optical profilometer. From the radius data the residual stress in the coating of each sample was calculated. The foil samples examined were of two different thicknesses, 0.3 mm and 0.5 mm. With the parameters of the project the foils of 0.3 mm were found most suitable. Furthermore, the method was compared to an already established method where depositions are made on thicker substrates, which are then ground to an appropriate thickness. A correlation factor between the two methods was calculated and found to be 0.91 ± 0.28. Finally, the possibility of adapting the method in running production was investigated. Cost and time analyses were conducted and both supported the applicability of the method. / Projektets syfte var att utveckla och utvärdera en metod för att mäta restspänningar i tunna PVD-beläggningar utifrån en redan befintlig idé. Tunna cirkulära prover av rostfritt stål belades med AlCrN genom PVD och radien på den utböjning som uppstod mättes med en optisk profilometer. Restspänningen bestämdes sedan utifrån den uppmätta radien. Folier av två olika tjocklekar, 0,3 mm och 0,5 mm, utvärderades. Med de processparametrar som användes i projektet visades att folien med tjocklek 0,3 mm var den bäst lämpade. Metoden jämfördes även med en etablerad metod där tjocka substrat beläggs och sedan slipas ned till lämplig tjocklek. En korrelationsfaktor som relaterar de två metoderna bestämdes till 0,91 ± 0,28. Slutligen undersöktes möjligheterna att använda metoden i löpande produktion. Kostnads- och tidsanalyser utfördes och resultaten stödjer metodens användbarhet.

Friction Stir Welding (FSW) is a new solid-state welding process that shows great promise for use in the aerospace and transportation industries. One of the primary benefits of this process is that mechanical properties of the base material are not as severely degraded as they are with conventional fusion welding. However, fatigue crack initiation and growth properties of the resulting weld nugget are not fully understood at this time. The primary goal of this project is to characterize the fatigue crack growth properties of friction stir welds in 6061-T6 aluminum as relates to the microstructural evolution of the weld. This was accomplished by producing friction stir welds and testing fatigue crack growth response in different crack orientations with respect to the weld. In addition, residual stress measurements were conducted for all cases, using both the crack compliance and contour methods. The results from the methods were compared in order to evaluate the accuracy of each method. Being an immature technology, the potential for discovery of new applications for the FSW process exist. With this in mind, novel applications of the FSW process, including the addition of particles during welding were explored. The first step was the investigation of property changes that occur when secondary cast phases are refined using the FSW process. The FSW process successfully refined all secondary phases in A380 and A356, producing an increase in hardness. Next, methods for the creation of particle metal matrix composites using FSW will be investigated. Nano-scale alumina particles were successfully added to the matrix and homogenously distributed. Using multiple weld passes through the composite was found to increase the uniformity of particle distribution. However, the alumina particle composite failed to provide any statistically significant hardness increase over the base material. The FSW process was also evaluated for weldability of traditionally difficult alloy systems. FSW was found to show very good weldability for dissimilar cast and wrought alloys, as well as for high-pressure die castings. Lastly, the feasibility of friction stir welding/processing in repairing crack defects in complex structural members in combination with cold-spray technology was determined. Friction Stir processing was used on a cold spray 6061-T6 block, resulting in significant increases in hardness over the base material, as well as a reduction in porosity. In addition, FSP was shown to eliminate crack-type defects in cold spray materials, a finding that has important applications in part repair. The deliverables of this work include an understanding of the fatigue crack growth response of FSW/FSP 6061-T6, as well as a feasibility study exploring novel uses for the FSW/FSP process. In addition, the deliverables include CNC code, fixtures, procedures, and analytical code for the creation and analysis of FSW/FSP joints. This will be important for the continuation of FSW/FSP work at WPI.

Stress in silicon structures plays an essential role in modern semiconductor technology. This stress has to be measured and due to the ongoing miniaturization in today’s semiconductor industry, the measuring method has to meet certain requirements. The present thesis deals with the question how Raman spectroscopy can be used to measure the state of stress in semiconductor structures. In the first chapter the relation between Raman peakshift and stress in the material is explained. It is shown that detailed stress maps with a spatial resolution close to the diffraction limit can be obtained in structured semiconductor samples. Furthermore a novel procedure, the so called Stokes-AntiStokes-Difference method is introduced. With this method, topography, tool or drift effects can be distinguished from stress related influences in the sample. In the next chapter Tip-enhanced Raman Scattering (TERS) and its application for an improvement in lateral resolution is discussed. For this, a study is presented, which shows the influence of metal particles on the intensity and localization of the Raman signal. A method to attach metal particles to scannable tips is successfully applied. First TERS scans are shown and their impact on and challenges for high resolution stress measurements on semiconductor structures is explained. / Spannungen in Siliziumstrukturen spielen eine entscheidende Rolle für die moderne Halbleitertechnologie. Diese mechanischen Verspannungen müssen gemessen werden und die fortlaufende Miniaturisierung in der Halbleiterindustrie stellt besondere Anforderungen an die benutzte Messmethode. Diese Arbeit beschäftigt sich mit dem Thema, inwieweit Raman Spektroskopie zur Spannungsmessung in Halbleiterstrukturen geeignet ist. Im ersten Kapitel wird der Zusammenhang zwischen Raman Peakverschiebung und mechanischer Spannung erläutert. Es wird gezeigt wie man detaillierte stress maps in strukturierten Halbleiterproben erhält mit einer Auflösung nahe am Diffraktionslimit. Darüber hinaus wird ein neuartiges Verfahren, die sogenannte Stokes-AntiStokes-Differenz Methode vorgestellt mit deren Hilfe man Einflüsse von Topographie, Geräteeffekten und Drift von den zu messenden Spannungszuständen in der Probe unterscheiden kann. Im nächsten Kapitel wird diskutiert, inwiefern der Ansatz von Tip-enhanced Raman Scattering (TERS), also spitzenverstärkter Raman Streuung genutzt werden kann um die laterale Auflösung bei Raman Spannungsmessungen zu erhöhen. Hierzu wird eine Studie präsentiert, die zeigt, welchen Einfluss Metallpartikel auf Erhöhung und Lokalisierung des Ramansignals haben. Eine Methode um Metallpartikel an scannbare Spitzen anzubringen wird erfolgreich angewendet. Erste TERS-Scans werden gezeigt und deren Bedeutung und Herausforderungen bei der hochaufgelösten Messung von Spannungen in Halbleiterstrukturen wird erläutert.

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No description available.

In rock constructions and mining it is important to know the current stress situation in the rock due to safety and construction reasons. Two of the widely used stress measurement methods are overcoring and hydraulic fracturing. Both methods are expensive, need new boreholes, and are complex and time consuming. The methods are also limited by the number of successfully achieved measurements series. An alternative method is therefore investigated by locally relieving stresses around the borehole wall using sawn slots. To determine the stresses in the rock, strain measurements will be done using optics and image processing of images taken before and after cutting of the slots. The images will be processed by a technique called Digital Image Correlation (DIC), a method where the pixels are fitted between the images by the greyscale. The thesis is roughly divided into three parts. The first part explains the basics of rock stresses and current stress measurement methods. The second part is a literature study of the theory behind optics and DIC. There is also a study about if it is possible to use optics from a smartphone and how it differs from a reference commonly used camera in DIC application. Last part consists of numerical calculations in 2D to investigate if there is a possibility to relieve the stress around the borehole walls by cutting slots. With the optics from a smartphone the borehole wall can be in focus on just a few millimeters distance. DIC is a well-developed method which has a good precision when being conducted right and with a good image quality. The combination of using a smartphone and DIC is, however, not fully investigated yet. Only one comparable study was found. It used a Sony tablet and measured the deformations instead of strains. However, that study showed that the measurement error was around 1% compared to the reference camera. When translating deformations into strains, it is most likely that the error will increase, because the error will also be affected from the difference in deformation before and after cutting the slots. The numerical part showed that it’s possible to relieve the stress at parts of the borehole walls for the investigated conditions. To fully relieve the stresses around the borehole wall, it is necessary to have two slots with a short c-c distance and relatively deep slots. In this case a c-c distance of 15 mm and slot depth of at least 25 mm are recommended. / Vid projekt inom berganläggningar och gruvor är det viktigt att känna till de rådande spänningar i berget i ett säkerhets- och konstruktionsperspektiv. I Sverige används framförallt två undersökningsmetoder - överborrning eller hydraulisk spräckning. Två metoder som dock är dyra och relativt få mätserier kan genomföras. En alternativ metod har därför undersökts där borrhålsväggen lokalt avlastas genom sågade slitsar. Töjningsmätning sker genom att fotografera borrhålsväggen innan och efter sågning av slitsarna. Därefter sker bildbehandling via Digital Image Correlation (DIC). En metod som jämför en pixels placerings förändring genom att matcha pixeln via gråskalan. Examensarbetet kan man säga är grovt indelat i tre delar. Den första delen innefattar teorin som handlar om bergspänningar samt nuvarande mätmetoder för att mäta bergsspänningar. Andra delen är en litteraturstudie som behandlar den bakomliggande teorin för optik och bildbehandling med DIC samt en kort undersökning om det är möjligt att använda den optiska tekniken som finns i en smartphone. Sista delen utgörs av numeriska modelleringar i 2D för att verifiera om det går att fullständigt avlasta ett borrhål genom sågade slitsar. Med optik som finns i en smartphone kan bergväggen vara i fokus på bara ett par millimeters avstånd. DIC i sig är en teknik som är så pass utvecklad att precisionen i mätningarna är väldigt god. Förutsatt att bildbehandling görs korrekt och bildkvalitén är god. Kombinationen med optik liknande den från smartphone och bildbehandling med DIC är dock inte fullständigt undersökt. Enbart en jämförbar studie har hittats där deformationsmätningar har gjort med hjälp av en Surfplatta från Sony. Denna undersökning visade att mätfelet mot en referenskamera är cirka 1%. Dock förstärks mätfelet vid töjningsmätningar. Förstärkningen beror dock även av deformationsskillnaden mellan innan och efter avlastning. Den numeriska delen har visat att det går att lokalt avlasta bergväggen fullständigt för det undersökta spänningsförhållandet. Dock krävs det att två slitsar sitter på ett litet c-c avstånd samt är relativt djupa. Två undersökta slitsuppsättningar har visat på fullständigt avlastning, samt ytterligare ett fall som skulle kunna vara användbart.