The goal of this work is to establish a life prediction methodology for thermomechanical loading of the Ni-base superalloy Mar-M247 over a larger temperature range than previous work. The work presented in this thesis extends the predictive capability of the Sehitoglu-Boismier unified thermo-viscoplasticity constitutive model and thermomechanical life model from a maximum temperature of 871C to a maximum temperature of 1038C. The constitutive model, which is suitable for predicting stress-strain history under thermomechanical loading, is adapted and calibrated using the response from isothermal cyclic experiments conducted at temperatures from 500C to 1038C at different strain rates with and without dwells. In the constitutive model, the flow rule function and parameters as well as the temperature dependence of the evolution equation for kinematic hardening are established. In the elevated temperature regime, creep and stress relaxation are critical behaviors captured by the constitutive model. The life model accounts for fatigue, creep, and environmental-fatigue damage under both isothermal and thermomechanical fatigue. At elevated temperatures, the damage terms must be calibrated to account for thermally activated damage mechanisms which change with increasing temperature. At lower temperatures and higher strain rates, fatigue damage dominates life prediction, while at higher temperatures and slower strain rates, environmental-fatigue and creep damage dominate life prediction. Under thermomechanical loading, both environmental-fatigue and creep damage depend strongly on the relative phasing of the thermal and mechanical strain rates, with environmental-fatigue damage dominating during out-of-phase thermomechanical loading and creep damage dominating in-phase thermomechanical loading. The coarse-grained polycrystalline microstructure of the alloy studied causes a significant variation in the elastic response, which can be linked to the crystallographic orientation of the large grains. This variation in the elastic response presents difficulties for both the constitutive and life models, which depend upon the assumption of an isotropic material. The extreme effects of a large grained microstructure on the life predictions is demonstrated, and a suitable modeling framework is proposed to account for these effects in future work.

O objetivo deste estudo foi confeccionar uma nova macroestrutura de implantes de Zircônia (Y- TZP) e Titânio (Grau 4) e posteriormente avaliar comparativamente a transmissão de força e a resistência flexural, submetidos à fadiga mecânica e termomecânica. Foram obtidos 33 implantes de Zircônia e de titânio Grau 4. As tensões geradas em torno dos implantes foram observadas em 3 espécimes inicialmente por meio de análise fotoelástica, com forca de 200N aplicada no longo eixo dos implantes. Em seguida, os implantes foram incluídos em resina de poliuretano (F-16, AXSON Technologies) com inclinação de 30° e aleatoriamente separados em grupos (n=10),, segundo o tipo de tratamento a que foram submetidos: Controle (sem tratamento) (Zr e Ti), fadiga mecânica (ZrM e TiM) e fadiga termomecânica (ZrTM e TiTM). A máquina de fadiga mecânica foi programada para aplicar carga de 133 N, com frequência de120 ciclos por minuto (2 Hz), totalizando 2.000.000 ciclos em cada espécime. A ciclagem térmica foi configurada com a temperatura mínima entre 2o a 5oC e temperatura máxima entre 50° a 55° C com exposição de 30 segundos para cada faixa e 5 segundos para troca dos líquidos. Após o ensaio de fadiga mastigatória, todos os grupos foram submetidos ao ensaio de tensão flexural. Os resultados foram submetidos à análise estatística (2-way ANOVA, teste de Bonferroni, p<0,05) e verificou-se que nao houve diferença estatisticamente significante na quantificação da transmissão de força entre os implantes de Zircônia e Titânio. Os implantes de Titânio apresentaram maior resistência flexural, com diferença estatisticamente significante (p<0.05) em relação aos implantes de Zircônia. Concluiu-se que foi possível obter um design de implante de zircônia compatível com as condições de forças aplicadas em ambiente bucal. A fadiga mecânica e termomecânica não influenciaram a resistência flexural dos implantes de Titânio nem dos implantes de Zircônia. / The aim of this study was to develop a new Zirconia (Y-TZP) and Titanium (Grade 4) implant macrostructure to make an accurate comparative evaluation of the stress transmission and flexural strength after both materials were subjected to mechanical and thermomechanical fatigue. Thirty three Zirconia and Titanium Grade 4 implants were obtained. A force of 200N was applied to the long axis of the implants and the distribution of the generated stress around implants was initially observed in three specimens by photoelastic analysis. Then, the implants were embedded in polyurethane resin (F-16, AXSON Technologies) with an inclination of 30°and randomly divided into groups (n = 10), according to the type of treatment they were subjected to: Control (no treatment ) (Zr and Ti), mechanical fatigue (ZRM and TiM) and thermomechanical fatigue (ZrTM and TiTM). The mechanical fatigue testing machine was programmed to apply a load of 133 N, with a frequency of 120 cycles per minute (2 Hz) and a total of 2,000,000 cycles in each specimen. The thermocycling was set with the minimum temperature between 2°-5°C and maximum temperature between 50°-55°C with 30 seconds exposure for each track and 5 seconds for the exchange of fluids. Following the fatigue test (chewing simulation), all groups were subjected to flexural strength test. The data were subjected to statistical analysis (2-way ANOVA, Bonferroni test, p <0.05) and the results showed no statistically significant difference between Zirconia and Titanium implants\'s stress transmission values. Titanium implants showed higher flexural strength, which was statistically significant (p <0.05) compared with Zirconia implants. It was concluded that it was possible to obtain a Zirconia implant design compatible with the forces applied in the oral environment. Moreover, the mechanical and thermomechanical fatigue had no influence on the flexural strength of both Titanium and Zirconia implants.

O objetivo do estudo foi avaliar a resistência de união à zircônia após diferentes tratamentos de superfície e o comportamento mecânico de pilares e coroas de zircônia associados aos mesmos tratamentos. Na primeira fase, 95 discos em zircônia foram obtidos e divididos em cinco grupos (n = 19): GC (grupo controle, sem nenhum tipo de tratamento); GAL (jateamento com partículas de Al2O3 antes da sinterização); GALS (jateamento com partículas de Al2O3 após sinterização); GRO (silanização com sistema Rocatec antes da sinterização) e GROS (silanização com sistema Rocatec após sinterização). Três amostras de cada grupo tiveram a superfície analisada em MEV e MCVL. Dez amostras de cada grupo foram submetidas a ensaio de microcisalhamento e as seis restantes foram submetidas à análise de interface por meio de MEV. A análise estatística utilizou modelo de regressão linear com efeitos mistos e teste de Tukey (p < 0,01). Na segunda fase, 70 pilares do tipo hexágono externo foram obtidos em zircônia e associados a coroas totais com copings de zircônia. Os conjuntos análogo-pilar-coroa também foram divididos em cinco grupos (n=14) e submetidos aos mesmos tratamentos previamente descritos. Ainda, foram realizadas mensurações para verificação da adaptação dos copings sobre os pilares e rugosidade superficial dos discos, copings e pilares em MCVL. Foi realizado ensaio de fadiga mecânica dos conjuntos com carga progressiva de 80, 120, 160, 200, 240, 280 e 320 N, frequência de 5 Hz, totalizando 20.000 ciclos em cada estágio. A ciclagem térmica foi realizada com temperaturas entre 5º C e 55º C. Após os ensaios mecânicos, os resultados foram submetidos à análise estatística (probabilidade de sobrevida, teste de Log-Rang, p < 0,05) Os resultados apontaram que o grupo ROS apresentou valores de resistência de união significativamente superiores (p < 0,01) e que a rugosidade superficial foi semelhante para discos e copings (p = 0,22) e para discos e pilares (p = 0,96), e diferente entre copings e pilares (p < 0,01). A desadaptação marginal foi maior para o grupo RO (p < 0,01) e a probabilidade de sobrevida dos conjuntos foi similar para todos os grupos testados (p = 0,57). Concluiu-se que a utilização do Rocatec aumenta os valores de resistência de união à zircônia, não compromete o comportamento mecânico do material e sua utilização é viável em peças já sinterizadas. / The aim of this study was to evaluate the bond strength to zirconia after different surface treatments and to evaluate the mechanical behavior of zirconia abutments and crowns associated with these treatments. In the first phase, 95 discs in zirconia were obtained and divided into five groups (n = 19): GC (control group, without any treatment), GAL (air particle abrasion with Al2O3 particles before sintering), GALS (air particle abrasion with Al2O3 particles after sintering), GRO (silanization with Rocatec system before sintering) and GROS (silanization with Rocatec system after sintering). Three samples of each group had the surfaces analyzed in SEM and CLSM. Ten samples of each group were subjected to microshear test and the other remaining six had their interface examined by SEM. The statistical analysis used a linear regression model with mixed effects and Tukey test (p <0.01). In the second stage, 70 external hex abutments were obtained in zirconia and associated with crowns and zirconia copings. The analog-abutment-crown assemblies were also divided into five groups (n = 14) and subjected to the same treatments described previously. Measurements to verify the adaptation of copings on the abutments and surface roughness of the discs, copings and abutments were performed in CLSM. A fatigue test was carried with progressive load of 80, 120, 160, 200, 240, 280 and 320 N, frequency of 5 Hz and 20,000 cycles at each stage. Thermal cycling was performed with temperatures between 5° C and 55° C. After mechanical tests, the results were subjected to statistical analysis (survival probability, Log-Rang test, p <0.05) The results showed that the ROS group had significantly higher bond strength values (p < 0.01) and that the surface roughness was similar for discs and copings (p = 0.22) and for discs and abutments (p = 0.96), and was different between copings and abutments (p < 0.01). The marginal gap was higher for RO group (p < 0.01) and the survival probability of the sets was similar for all tested groups (p = 0.57). It was concluded that the use of Rocatec increases the bond strength values to zirconia, does not compromise the mechanical behavior of the material and its use is now feasible in sintered parts.

O objetivo do estudo foi avaliar a resistência de união à zircônia após diferentes tratamentos de superfície e o comportamento mecânico de pilares e coroas de zircônia associados aos mesmos tratamentos. Na primeira fase, 95 discos em zircônia foram obtidos e divididos em cinco grupos (n = 19): GC (grupo controle, sem nenhum tipo de tratamento); GAL (jateamento com partículas de Al2O3 antes da sinterização); GALS (jateamento com partículas de Al2O3 após sinterização); GRO (silanização com sistema Rocatec antes da sinterização) e GROS (silanização com sistema Rocatec após sinterização). Três amostras de cada grupo tiveram a superfície analisada em MEV e MCVL. Dez amostras de cada grupo foram submetidas a ensaio de microcisalhamento e as seis restantes foram submetidas à análise de interface por meio de MEV. A análise estatística utilizou modelo de regressão linear com efeitos mistos e teste de Tukey (p < 0,01). Na segunda fase, 70 pilares do tipo hexágono externo foram obtidos em zircônia e associados a coroas totais com copings de zircônia. Os conjuntos análogo-pilar-coroa também foram divididos em cinco grupos (n=14) e submetidos aos mesmos tratamentos previamente descritos. Ainda, foram realizadas mensurações para verificação da adaptação dos copings sobre os pilares e rugosidade superficial dos discos, copings e pilares em MCVL. Foi realizado ensaio de fadiga mecânica dos conjuntos com carga progressiva de 80, 120, 160, 200, 240, 280 e 320 N, frequência de 5 Hz, totalizando 20.000 ciclos em cada estágio. A ciclagem térmica foi realizada com temperaturas entre 5º C e 55º C. Após os ensaios mecânicos, os resultados foram submetidos à análise estatística (probabilidade de sobrevida, teste de Log-Rang, p < 0,05) Os resultados apontaram que o grupo ROS apresentou valores de resistência de união significativamente superiores (p < 0,01) e que a rugosidade superficial foi semelhante para discos e copings (p = 0,22) e para discos e pilares (p = 0,96), e diferente entre copings e pilares (p < 0,01). A desadaptação marginal foi maior para o grupo RO (p < 0,01) e a probabilidade de sobrevida dos conjuntos foi similar para todos os grupos testados (p = 0,57). Concluiu-se que a utilização do Rocatec aumenta os valores de resistência de união à zircônia, não compromete o comportamento mecânico do material e sua utilização é viável em peças já sinterizadas. / The aim of this study was to evaluate the bond strength to zirconia after different surface treatments and to evaluate the mechanical behavior of zirconia abutments and crowns associated with these treatments. In the first phase, 95 discs in zirconia were obtained and divided into five groups (n = 19): GC (control group, without any treatment), GAL (air particle abrasion with Al2O3 particles before sintering), GALS (air particle abrasion with Al2O3 particles after sintering), GRO (silanization with Rocatec system before sintering) and GROS (silanization with Rocatec system after sintering). Three samples of each group had the surfaces analyzed in SEM and CLSM. Ten samples of each group were subjected to microshear test and the other remaining six had their interface examined by SEM. The statistical analysis used a linear regression model with mixed effects and Tukey test (p <0.01). In the second stage, 70 external hex abutments were obtained in zirconia and associated with crowns and zirconia copings. The analog-abutment-crown assemblies were also divided into five groups (n = 14) and subjected to the same treatments described previously. Measurements to verify the adaptation of copings on the abutments and surface roughness of the discs, copings and abutments were performed in CLSM. A fatigue test was carried with progressive load of 80, 120, 160, 200, 240, 280 and 320 N, frequency of 5 Hz and 20,000 cycles at each stage. Thermal cycling was performed with temperatures between 5° C and 55° C. After mechanical tests, the results were subjected to statistical analysis (survival probability, Log-Rang test, p <0.05) The results showed that the ROS group had significantly higher bond strength values (p < 0.01) and that the surface roughness was similar for discs and copings (p = 0.22) and for discs and abutments (p = 0.96), and was different between copings and abutments (p < 0.01). The marginal gap was higher for RO group (p < 0.01) and the survival probability of the sets was similar for all tested groups (p = 0.57). It was concluded that the use of Rocatec increases the bond strength values to zirconia, does not compromise the mechanical behavior of the material and its use is now feasible in sintered parts.

O objetivo deste estudo foi confeccionar uma nova macroestrutura de implantes de Zircônia (Y- TZP) e Titânio (Grau 4) e posteriormente avaliar comparativamente a transmissão de força e a resistência flexural, submetidos à fadiga mecânica e termomecânica. Foram obtidos 33 implantes de Zircônia e de titânio Grau 4. As tensões geradas em torno dos implantes foram observadas em 3 espécimes inicialmente por meio de análise fotoelástica, com forca de 200N aplicada no longo eixo dos implantes. Em seguida, os implantes foram incluídos em resina de poliuretano (F-16, AXSON Technologies) com inclinação de 30° e aleatoriamente separados em grupos (n=10),, segundo o tipo de tratamento a que foram submetidos: Controle (sem tratamento) (Zr e Ti), fadiga mecânica (ZrM e TiM) e fadiga termomecânica (ZrTM e TiTM). A máquina de fadiga mecânica foi programada para aplicar carga de 133 N, com frequência de120 ciclos por minuto (2 Hz), totalizando 2.000.000 ciclos em cada espécime. A ciclagem térmica foi configurada com a temperatura mínima entre 2o a 5oC e temperatura máxima entre 50° a 55° C com exposição de 30 segundos para cada faixa e 5 segundos para troca dos líquidos. Após o ensaio de fadiga mastigatória, todos os grupos foram submetidos ao ensaio de tensão flexural. Os resultados foram submetidos à análise estatística (2-way ANOVA, teste de Bonferroni, p<0,05) e verificou-se que nao houve diferença estatisticamente significante na quantificação da transmissão de força entre os implantes de Zircônia e Titânio. Os implantes de Titânio apresentaram maior resistência flexural, com diferença estatisticamente significante (p<0.05) em relação aos implantes de Zircônia. Concluiu-se que foi possível obter um design de implante de zircônia compatível com as condições de forças aplicadas em ambiente bucal. A fadiga mecânica e termomecânica não influenciaram a resistência flexural dos implantes de Titânio nem dos implantes de Zircônia. / The aim of this study was to develop a new Zirconia (Y-TZP) and Titanium (Grade 4) implant macrostructure to make an accurate comparative evaluation of the stress transmission and flexural strength after both materials were subjected to mechanical and thermomechanical fatigue. Thirty three Zirconia and Titanium Grade 4 implants were obtained. A force of 200N was applied to the long axis of the implants and the distribution of the generated stress around implants was initially observed in three specimens by photoelastic analysis. Then, the implants were embedded in polyurethane resin (F-16, AXSON Technologies) with an inclination of 30°and randomly divided into groups (n = 10), according to the type of treatment they were subjected to: Control (no treatment ) (Zr and Ti), mechanical fatigue (ZRM and TiM) and thermomechanical fatigue (ZrTM and TiTM). The mechanical fatigue testing machine was programmed to apply a load of 133 N, with a frequency of 120 cycles per minute (2 Hz) and a total of 2,000,000 cycles in each specimen. The thermocycling was set with the minimum temperature between 2°-5°C and maximum temperature between 50°-55°C with 30 seconds exposure for each track and 5 seconds for the exchange of fluids. Following the fatigue test (chewing simulation), all groups were subjected to flexural strength test. The data were subjected to statistical analysis (2-way ANOVA, Bonferroni test, p <0.05) and the results showed no statistically significant difference between Zirconia and Titanium implants\'s stress transmission values. Titanium implants showed higher flexural strength, which was statistically significant (p <0.05) compared with Zirconia implants. It was concluded that it was possible to obtain a Zirconia implant design compatible with the forces applied in the oral environment. Moreover, the mechanical and thermomechanical fatigue had no influence on the flexural strength of both Titanium and Zirconia implants.

Die Eigenschaften der kommerziell verfügbaren Hochtemperaturwerkstoffe bestimmen den Wirkungsgrad und die Leistungsfähigkeit von Flug- und Industriegasturbinen sowie Motoren. Da die breit eingesetzten Nickelbasis-Werkstoffe mit etwa 8-8,5 g/cm^3 eine verhältnismäßig hohe Dichte aufweisen, wird seit Jahrzehnten nach alternativen Werkstoffen gesucht. Da besonders die Titanaluminide, speziell die stark Nb-haltigen gamma-TiAl-Legierungen (TNB-Legierungen), mit einer Dichte von ca. 4,5 g/cm^3 einen beträchtlichen Dichtegewinn gegenüber den Nickelbasis-Superlegierungen bieten, haben Legierungen auf dieser Basis das größte Potenzial, um die Nickelbasis-Superlegierungen teilweise zu ersetzen. Im Fluggasturbinenbau ist die Anwendung für den hinteren Teil des Hochdruckverdichters und die letzten Stufen der Turbine angedacht. Dabei sollen Schaufeln, Gehäuse und Anbauteile aus modernen gamma-TiAl-Legierungen zum Einsatz kommen. Für die Auslegung dieser Bauteile sind umfassende Kenntnisse des Werkstoffverhaltens zwingend notwendig. Treten im Betrieb hohe Temperaturgradienten in den Bauteilen auf, so muss besonders auch das thermomechanische Ermüdungsverhalten betrachtet werden. Dieses stellt insbesondere für den Einsatz in Gasturbinen einen relevanten Schädigungsmechanismus dar. Inhalt dieser Arbeit war die Charakterisierung des thermomechanischen Verformungs- und Ermüdungsverhaltens der modernen gamma-TiAl-Legierung TNB-V5. Dabei wurden die Einflüsse der Mikrostruktur, der Phasenbeziehung zwischen thermischer und mechanischer Beanspruchung, des Temperaturbereiches und der Höhe der mechanischen Beanspruchung untersucht. Zum Verständnis der Ergebnisse wurden moderne Methoden der Mikrocharakterisierung angewandt. Zur Beschreibung des Lebensdauerverhaltens wurden der Schädigungsparameter PSWT nach Smith, Watson und Topper und der Schädigungsparameter PHL nach Haibach und Lehrke erfolgreich angewandt. Es wurden folgende, wesentlich über den bisherigen Stand des Wissens hinausgehende Erkenntnisse gewonnen: Eine Beanspruchung mit der Phasenbeziehung Clockwise-Diamond (CD) bzw. Counter-Clockwise-Diamond (CCD) führt im Gegensatz zur In-Phase- (IP) oder Out-of-Phase- (OP) Beanspruchung nur zu geringen Unterschieden zwischen den Beträgen der Ober- und der Unterspannung. Unter CD- und CCD-Beanspruchung kommt es zu nahezu keinen bzw. im Vergleich zur IP- und OP-Beanspruchung deutlich geringeren Zug- oder Druckmittelspannungen. Des Weiteren unterscheiden sich die Spannungs-Dehnungs-Hysteresekurven unter CD- bzw. CCD-Beanspruchung nur sehr wenig. Die Bruchlastspielzahlen der CD- und CCD-Versuche liegen immer zwischen denen der IP- und OP-Versuche. Für eine Lebensdauervorhersage unter thermomechanischer Beanspruchung sind die Schädigungsparameter PSWT nach Smith, Watson und Topper und PHL nach Haibach und Lehrke gut geeignet, wenn der Versuchs- bzw. Anwendungstemperaturbereich Temperaturen oberhalb des Spröd-Duktil-Überganges (ca. 750°C) beinhaltet. Ist dies der Fall, dann weichen die experimentell ermittelten Lebensdauern im betrachteten Bereich (Bruchlastspielzahl ca. 50 – 3000) maximal um den Faktor ±3 von den vorhergesagten Werten ab. Der Einfluss der Mikrostruktur auf das zyklische Verformungs- und Ermüdungsverhalten ist unter den betrachteten Bedingungen überraschend gering. Die Mikrostrukturen Near-Gamma und Duplex zeigen unter allen Versuchsbedingungen vergleichbare Lebensdauern, während das Fully-Lamellar-Gefüge tendenziell etwas höhere Lebensdauern aufweist. Weiterhin stellen die gewonnenen Ergebnisse eine wertvolle Datenbasis für die Auslegung von thermomechanisch beanspruchten Komponenten im Turbinen- und Motorenbau dar.

Les transistors IGBT sont les composants semi-conducteurs de puissance les plus couramment utilisés dans les fonctions de l'électronique de puissance. Ils sont fréquemment assemblés dans des modules contenant plusieurs puces et réalisant l'interconnexion à la fois électrique et thermique avec l'environnement. Dans de nombreuses applications, ces modules sont soumis à un cyclage thermique actif généré par les variations du régime de fonctionnement du système. Ceci est à l'origine de différentes dégradations d'origine thermomécaniques pouvant mener à la défaillance. Les tests de vieillissement sont l'un des moyens permettant de mieux comprendre les mécanismes de dégradations en imposant des conditions de stress connues mais également de construire des modèles de fiabilité comportementaux utiles dans l'estimation de durée de vie des systèmes.Le présent travail décrit la mise en œuvre d'une méthode de test originale destinée à des modules IGBT de la gamme 600V-200A et basée sur l'utilisation d'onduleurs fonctionnant en modulation de largeur d'impulsion. Elle exploite la variation de température de jonction provoquée par cette modulation pour générer un cyclage thermique d'une fréquence très supérieure (2Hz à 10Hz) à celles habituellement utilisées pour ce type de test. Ceci permet de réduire considérablement la durée de ces tests et d'accéder à des gammes basses de l'amplitude des cycles thermiques.Les essais de vieillissement imposent de suivre l'évolution de paramètres indicateurs afin d'estimer régulièrement l'état des composants testés et d'appliquer des conditions d'arrêt. Le paramètre utilisé dans le présent travail est la tension VCE des IGBT, qui est un bon révélateur de l'état des fils de bondings, maillons faibles de ces modules. En complément du développement de la méthode de cyclage proprement-dite, un dispositif de suivi automatique du paramètre VCE a été développé afin de limiter la durée des phases de caractérisations correspondantes. Ce dispositif permet également de mesurer la température de jonction de façon indirecte et de reconstruire le profil de température dynamique pendant le cyclage.Cet ensemble a permis d'obtenir des résultats exploitables sur une trentaine d'échantillons avec des amplitudes de cycle comprises entre 30°C et 50°C. Ils mettent en évidence un seul type de dégradation, la fissuration des attaches entre les fils de bonding et la métallisation d'émetteur avec, dans certains cas, le décollement complet du fil (lift-off). Des essais à différentes fréquences de cyclage pour la même amplitude ont été réalisés sur un groupe de ces échantillons. Si le nombre d'échantillons consacrés à comparaison n'est pas encore réellement suffisant, les résultats obtenus sont similaires et semblent donc démontrer que la fréquence de test n'impacte pas le mode de vieillissement dans la gamme de température étudiée. Cette observation est une première validation de la pertinence de la méthode proposée qui permet de réduire d'un facteur cinq à dix les durées de test. / IGBT transistors are the most used power semiconductor devices in power electronics and are often integrated in power modules to constitute basic switching functions. In various applications, IGBT power modules suffer thermal cycling (or power cycling) due to variations of operating conditions. This power cycling induces thermo mechanical stress that can lead to damages and then, to failures. Ageing tests are a means to identify and analyze the degradation mechanisms due to power cycling by imposing calibrated test conditions. In addition, their results can be used to establish empiric lifetime models that are useful for power converter designers.The present work describes the implementation of an ageing test method dedicated to IGBT modules operating in the 600V-200A range. This method takes advantage of particular operating conditions generated by pulse width modulation inverters in which the IGBT modules to be tested are introduced. The modulation induces a variation of IGBT die temperature, i.e. a power cycling, of which the frequency is significantly higher (2Hz to 10Hz) than the operating frequencies of classical test systems. By using this technique, the test length is reduced while low values of thermal amplitude can be reached.Throughout the ageing tests, the monitoring of ageing indicators is required to evaluate the sample health and to stop the operation when predefined conditions are reached. In the present work, the ageing indicator is the on-state voltage VCE across the IGBT device that is relevant in regard with wire bond degradations. Therefore, as a complement of the fast test method, an automated VCE monitoring system has been developed in order to fully take benefit of the high test-speed. In addition, this system is able to measure the junction temperature and to provide the temperature profile during the power cycling.This test bench has made possible the ageing process of three dozen of samples by applying thermal swing amplitudes in the 30°C-50°C range, that is not reachable with classical test benches operating in low frequency because of the unacceptable test length. The results show that only one kind of damage is generated by the present test conditions, i.e. the degradation of attaches between the emitter metallization and the wire bonds. In many case, complete lift-off have been observed. Some samples have been used to evaluate the influence of thermal swing frequency on the results. The latter are unchanged when the frequency varies between 2Hz and 0.2Hz, therefore it is a first validation of the fast test relevance.

Die Eigenschaften der kommerziell verfügbaren Hochtemperaturwerkstoffe bestimmen den Wirkungsgrad und die Leistungsfähigkeit von Flug- und Industriegasturbinen sowie Motoren. Da die breit eingesetzten Nickelbasis-Werkstoffe mit etwa 8-8,5 g/cm^3 eine verhältnismäßig hohe Dichte aufweisen, wird seit Jahrzehnten nach alternativen Werkstoffen gesucht. Da besonders die Titanaluminide, speziell die stark Nb-haltigen gamma-TiAl-Legierungen (TNB-Legierungen), mit einer Dichte von ca. 4,5 g/cm^3 einen beträchtlichen Dichtegewinn gegenüber den Nickelbasis-Superlegierungen bieten, haben Legierungen auf dieser Basis das größte Potenzial, um die Nickelbasis-Superlegierungen teilweise zu ersetzen. Im Fluggasturbinenbau ist die Anwendung für den hinteren Teil des Hochdruckverdichters und die letzten Stufen der Turbine angedacht. Dabei sollen Schaufeln, Gehäuse und Anbauteile aus modernen gamma-TiAl-Legierungen zum Einsatz kommen. Für die Auslegung dieser Bauteile sind umfassende Kenntnisse des Werkstoffverhaltens zwingend notwendig. Treten im Betrieb hohe Temperaturgradienten in den Bauteilen auf, so muss besonders auch das thermomechanische Ermüdungsverhalten betrachtet werden. Dieses stellt insbesondere für den Einsatz in Gasturbinen einen relevanten Schädigungsmechanismus dar. Inhalt dieser Arbeit war die Charakterisierung des thermomechanischen Verformungs- und Ermüdungsverhaltens der modernen gamma-TiAl-Legierung TNB-V5. Dabei wurden die Einflüsse der Mikrostruktur, der Phasenbeziehung zwischen thermischer und mechanischer Beanspruchung, des Temperaturbereiches und der Höhe der mechanischen Beanspruchung untersucht. Zum Verständnis der Ergebnisse wurden moderne Methoden der Mikrocharakterisierung angewandt. Zur Beschreibung des Lebensdauerverhaltens wurden der Schädigungsparameter PSWT nach Smith, Watson und Topper und der Schädigungsparameter PHL nach Haibach und Lehrke erfolgreich angewandt. Es wurden folgende, wesentlich über den bisherigen Stand des Wissens hinausgehende Erkenntnisse gewonnen: Eine Beanspruchung mit der Phasenbeziehung Clockwise-Diamond (CD) bzw. Counter-Clockwise-Diamond (CCD) führt im Gegensatz zur In-Phase- (IP) oder Out-of-Phase- (OP) Beanspruchung nur zu geringen Unterschieden zwischen den Beträgen der Ober- und der Unterspannung. Unter CD- und CCD-Beanspruchung kommt es zu nahezu keinen bzw. im Vergleich zur IP- und OP-Beanspruchung deutlich geringeren Zug- oder Druckmittelspannungen. Des Weiteren unterscheiden sich die Spannungs-Dehnungs-Hysteresekurven unter CD- bzw. CCD-Beanspruchung nur sehr wenig. Die Bruchlastspielzahlen der CD- und CCD-Versuche liegen immer zwischen denen der IP- und OP-Versuche. Für eine Lebensdauervorhersage unter thermomechanischer Beanspruchung sind die Schädigungsparameter PSWT nach Smith, Watson und Topper und PHL nach Haibach und Lehrke gut geeignet, wenn der Versuchs- bzw. Anwendungstemperaturbereich Temperaturen oberhalb des Spröd-Duktil-Überganges (ca. 750°C) beinhaltet. Ist dies der Fall, dann weichen die experimentell ermittelten Lebensdauern im betrachteten Bereich (Bruchlastspielzahl ca. 50 – 3000) maximal um den Faktor ±3 von den vorhergesagten Werten ab. Der Einfluss der Mikrostruktur auf das zyklische Verformungs- und Ermüdungsverhalten ist unter den betrachteten Bedingungen überraschend gering. Die Mikrostrukturen Near-Gamma und Duplex zeigen unter allen Versuchsbedingungen vergleichbare Lebensdauern, während das Fully-Lamellar-Gefüge tendenziell etwas höhere Lebensdauern aufweist. Weiterhin stellen die gewonnenen Ergebnisse eine wertvolle Datenbasis für die Auslegung von thermomechanisch beanspruchten Komponenten im Turbinen- und Motorenbau dar.

A vast array of high value parts in land- and air-based turbomachinery are subjected to non-isothermal cycling in the presence of mechanical loading. Crack initiation, growth and eventual failure more significantly reduce life in these components compared to isothermal conditions. More accurate simulation of the stress and strain evolution at critical locations of components, as well as test specimens, can lead to a more accurate prediction of remaining life to a structural integrity specialists. The focus of this thesis is to characterize the effects of thermomechanical fatigue (TMF) on generic turbomachinery alloy. An expression that can be used to estimate the maximum and minimum stress under a variety of loading conditions is formulated. Analytical expressions developed here are modifications of classic mechanics of materials methods (e.g. Neuber's Rule and Ramberg-Osgood). The novel models are developed from a collection of data based on parametric finite element analysis to encompass the complex load history present in turbine service conditions. Relevance of the observations and formulated solutions are also explored for the case of a tensile specimen containing a v-shaped notch. Accurate estimations of non-isothermal fatigue presented here endeavor to improve component lifing and decrease maintenance costs.

O estudo avaliou a efetividade de tratamentos de superfície na modificação superficial e adesão da zircônia ao cimento resinoso; a estabilidade de união após ciclagem termomecânica entre coroas metal free com copings em zircônia ou coroas monolíticas em zircônia e pilares personalizados do mesmo material, submetidos a tratamento superficial, e a influência destes na sobrevida dos sistemas protéticos após fadiga termomecânica acelerada. A pesquisa foi desenvolvida em 2 etapas. Na primeira, discos de zircônia foram distribuídos em sete grupos (n=6): G1 (Rocatec); G2 (ácido hidrofluorídrico 40%, 210 segundos); G3 (ácido hidrofluorídrico 40%, 210 segundos + Rocatec); G4 (nanopartícula ZrO2); G5 (nanopartícula SiO2); G6 (nanopartícula SiO2ZrO2); G7 (nanopartícula SiO2ZrO2 + silano). Uma amostra por grupo (n=1) foi analisada por espectroscopia infravermelho (FTIR), difração de raios-x (DRX) e microscopia eletrônica de varredura (MEV). As demais, submetidas a microscopia confocal a laser (n=5) para determinação da rugosidade superficial (Ra) e teste de cisalhamento. Molhabilidade e energia de superfície foram desenvolvidas em triplicata (n=3). G1, G3, G5 e G7 apresentaram valores de resistência ao cisalhamento superiores aos demais. Os melhores resultados definiram os tratamentos da etapa seguinte. Na segunda etapa, 162 análogos de implante conexão tipo Morse foram utilizados. Sobre eles, instaladas bases de titânio conectando pilar de zircônia ao análogo. Os 162 pilares foram distribuídos em 2 grupos de acordo com o ensaio: ciclagem termomecânica ou fadiga termomecânica acelerada. Para cada ensaio, duas modalidades restauradoras foram planejadas (Mono - coroa monolítica em zircônia, Pren - coping em zircônia + cobertura de vitrocerâmica fluorapatita). Pilares foram distribuídos a depender do tratamento recebido: MonoRo (Rocatec), MonoSi (nanopartícula SiO2), MonoSiZr (nanopartícula SiO2ZrO2 + silano). Grupo Pren recebeu os mesmos tratamentos. Sobre pilares, foram cimentadas coroas. Coroas monolíticas, copings e pilares foram obtidos via CAD/CAM. A adesão foi quantificada por teste de resistência à tração após ciclagem termomecânica (n=9) (2x106 ciclos, 2Hz, 120N e ciclos térmicos de 5º-55ºC). Valores de resistência à tração e padrões de falha obtidos foram registrados. Não foram encontradas diferenças significantes entre grupos para resistência à tração, mas o comportamento médio da força foi diferente nos grupos dependendo da falha. Sobrevida dos conjuntos foi analisada após fadiga termomecânica acelerada (n=18) (cargas progressivas a cada 2x104 ciclos de 80, 120, 160, 200, 240, 280 e 320N em 5Hz até 14x104 ou a falha, com ciclos térmicos de 5º- 55ºC). Resistência à fadiga foi comparada pela probabilidade de sobrevivência em cada intervalo. Padrões de falha foram classificados em ambos testes e amostras representativas de cada falha analisadas em MEV. MonoRo e MonoSiZr são semelhantes e têm maior probabilidade de sobrevivência que os demais. Pertencer a PrenSiZr, MonoSi, PrenRo ou PrenSi diminui a probabilidade de sobrevivência. / The study evaluated the effectiveness of surface treatments in surface modification and zirconia adhesion to resin cement; the bonding stability after thermomechanical cycling between free metal crowns with zirconia copings or monolithic zirconia crowns and customized abutments of the same material, subjected to surface treatments, and their influence in the survival of prosthetic systems after accelerated thermomechanical fatigue. The research was developed in 2 stages. In the first, zirconia discs were distributed in seven groups (n = 6): G1 (Rocatec); G2 (hydrofluoric acid 40%, 210 seconds); G3 (hydrofluoric acid 40%, 210 seconds + Rocatec); G4 (nanoparticle ZrO2); G5 (SiO2 nanoparticle); G6 (SiO2ZrO2 nanoparticle); G7 (SiO2ZrO2 nanoparticle + silane). One sample per group (n = 1) was analyzed by infrared spectroscopy (FTIR), X-ray diffraction (XRD) and scanning electron microscopy (SEM). The others were submitted to laser confocal microscopy (n = 5) for determination of surface roughness (Ra) and shear test. Wettability and surface energy were developed in triplicate (n = 3). G1, G3, G5 and G7 presented higher values of shear strength than the others. The best results defined the treatments of the next stage. In the second stage, 162 Morse type implant analogues were used. On them, installed a titanium base, connecting zirconia abutment to analog. The 162 abutments were distributed in 2 groups according to the test: thermomechanical cycling or accelerated thermomechanical fatigue. For each test, two restorative modalities were planned (Mono - monolithic zirconia, Pren - zirconia coping + vitroceramic fluorapatite revestment). Abutments were distributed depending on the treatment received: MonoRo (Rocatec), MonoSi (nanoparticle SiO2), MonoSiZr (nanoparticle SiO2ZrO2 + silane). The Pren Group received the same treatments. Crowns were cemented on abutments. Monolithic crowns, copings and abutments were obtained by CAD/CAM. The adhesion was quantified by tensile strength test after thermomechanical cycling (n = 9) (2x106 cycles, 2Hz, 120N and thermal cycles of 5º-55ºC). Values of tensile strength and obtained failure patterns were recorded. No significant differences were found between groups for tensile strength, but mean force behavior was different in groups depending on failure. The survival of the sets was analyzed after accelerated thermomechanical fatigue (n = 18) (progressive loads every 2x104 cycles of 80, 120, 160, 200, 240, 280 and 320N in 5Hz up to 14x104 or failure, with thermal cycles of 5º- 55ºC). Fatigue resistance was compared by the probability of survival at each interval. Failure patterns were classified in both tests and representative samples of each failure analyzed in SEM. MonoRo and MonoSiZr are similar and more likely to survive than the others. Belonging to PrenSiZr, MonoSi, PrenRo or PrenSi reduces the probability of survival.