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<p>Electropolishing is a commonly used method of mitigating surface roughness and yielding a polished appearance. One of the first described and most studied of electropolishing systems is the anodization of copper in phosphoric acid. Under normal conditions this reduces copper surface roughness substantially; however deviating from optimal electropolishing conditions can promote the development of semi-ordered surface roughness. Anodizing copper substrates in 98-100% H₃PO₄ solutions generated feature heights ranging from 0.5 - 2µm and surface area increases in excess of 30% were obtained. The samples demonstrated a macroscopic optical dullness characteristic of this type of surface roughening. Investigations as to their applicability in surface enhanced Raman spectroscopy and electron field emission were conducted. And while their formation mechanism is still speculated on, it is believed that oxygen evolution and subsequent bubble formation plays a key role. Electrochemical and microscopic imaging techniques were the primary methodologies used to probe the optical dulling phenomenon. With data obtained from experiments utilizing these techniques and others a qualitative mechanism is proposed.</p> / Master of Science (MSc)

<p><strong>Abstract</strong></p> <p>The objective of this research is to develop an understanding of the mechanical behavior, failure and microstructure evolution of aluminum tubes under internal pressure loading, and to delineate the physical and mechanical origins of spatially-localized plastic deformation. Traditional approaches to the study of plastic instabilities, necking and failure have either been based on kinematic considerations, such as finite strain effects and geometric softening, or physics-based concepts. In this study, we develop a framework that combines both approaches to investigate the tube deformation and failure behavior at various loading conditions.</p> <p>A rate-dependent dislocation-based MTS model has been developed to study the tube hydro-forming process at high temperatures and at various strain rates. The development and application of the MTS model led to an advanced industrial application of PRF bottle forming, which has been fully investigated. This simulation shows a good agreement between experimental results and prediction. The model has been used extensively throughout the PRF bottle development, with several patent applications.</p> <p>The crystal plasticity based finite element model is selected to simulate surface roughening and localized necking in aluminum alloy tubes under internal pressure. The measured electron backscatter diffraction (EBSD) data are directly incorporated into the finite element model and the constitutive response at an integration point is described by the single crystal plasticity theory. The effects of the spatial grain orientation distribution, strain rate sensitivity, work hardening, and initial surface topography on surface roughening and necking are discussed. It is demonstrated that while localized necking is very sensitive to both the initial texture and its spatial orientation distribution, the initial surface topography has only a small influence on necking, but a large influence on surface roughness of the formed product.</p> <p>An elastic-viscoplastic based finite element model has been developed to study the necking behavior of tube expansion for rate dependent monolithic materials and laminated materials during dynamic loading. Numerical study shows that a high strain rate sensitivity can significantly delay the onset of necking for both monolithic and laminated sheets, and affect the multiple-neck formation in high speed dynamic loading. The model also shows that higher volume fractions of a clad layer with positive rate sensitivity material in laminated sheet could improve the sheet ductility as well.</p> <p>A commercial FE package, ABAQUS, is employed as a finite element method solver in this research work, and several user subroutines were developed to model various hydro-forming processes. Interfaces between the ABAQUS user subroutine UMAT and the ABAQUS main code are developed to allow further extension of the current method.</p> / Doctor of Philosophy (PhD)

This thesis investigates the impact of interface surface treatment methods for use in the Virginia Inverted T-Beam bridge system. The specific system consists of precast beams with thin bottom flanges placed next to one another, with a cast-in-place slab on top. Previous research has shown that the strength of this system after cyclic loading is highly dependent upon the shear strength of the interface between the precast and cast-in-place sections, especially for the adhesion-based connection configuration. The approval of this bridge system for use in bridges with high daily traffic volumes hinges on the verification of its strength and durability for a 50-year lifespan. The shear strength of ten different surface textures was tested using push-off tests to determine which interface roughening methods would prove adequate for use in the bridge system. The strength was found to depend on both the amplitude and the geometry of the undulations on the beam-to-slab interface. Using this information, a texture was selected for a new trial of the adhesion-based connection configuration, and a test specimen was constructed. After completing cyclic loading to simulate the design life of the bridge, it was found that the system achieved a strength similar to previous monotonically loaded specimens. It was concluded that the bridge is safe for use in high daily traffic areas provided that a surface roughening with adequate shear strength is used. / Master of Science