Advances in test and measurement of the interface adhesion and bond strengths in coating-substrate systems, emphasising blister and bulk techniques

In this paper, recent advances in the minimum-destructive testing of the adhesion of coating-substrate systems are reviewed, focusing on key techniques such as micro- and nano-scale levels of indentation, scratching, laser-induced wave shock, as well as the blister and buckle approach. Along with adhesion failure tests, the latest and most extensive applications of the adhesion test methods in nano-, micro- and bulk-coating technology and the associated techniques to determine the minimum damage defects left on the coatings are discussed and their use reviewed

Crashworthiness assessment considering the dynamic damage and failure of a dual phase automotive steel

Analyzing crash worthiness of the automotive parts has been posing a great challenge in the sheet metal and automotive industry since several decades. The present contribution will focus on one of the most urging challenges of the crash worthiness simulations, namely, an enhanced constitutive formulation to predict the failure and cracking of structural parts made from high strength steel sheets under impact. A hybrid extended Modified Bai Wierzbicki damage plasticity model is devised to this end. The material model calibrated using the experimental data covering high strain rate deformation, damage and failure successfully predicted the instability and subsequent response of the crash box under impact. Simulation results provide the deformation shape and deformation energy in order to predict and evaluate the vehicle crashworthiness. The simulations further helped in discovering the irrefutable impact of strain rate and stress state on the impact response of the auto-body structure. The strain rate is found to adequately affect the energy absorption capacity of the crash box structure both in terms of impact load and fold formation whereas the complex stress state has a direct association to the development of instability within the structure and early damage appearance within the folds

Degradation of alumina and zirconia toughened alumina (ZTA) hip prostheses tested under microseparation conditions in a shock device

This paper considers the degradation of alumina and zirconia toughened alumina vs. alumina for hip implants. The materials are as assumed to be load bearing surfaces subjected to shocks in wet conditions. The load is a peak of force; 9 kN was applied over 15 ms at 2 Hz for 800,000 cycles. The volumetric wear and roughness are lower for ZTA than for alumina. The long ZTA ageing did not seem to have a direct influence on the roughness. The ageing increased the wear volumes of ZTA and it was found to have a higher wear resistance compared to alumina.Comment: International Conference on BioTribology (ICoBT 2011), Londres, 18 au 21 septembre 2011, Londres : United Kingdom (2011

Influence of Microstructure on Damage Behavior of Sound Absorbing Ceramics

Porous sound-absorbing ceramics contribute to the passive damping of thermo-acoustic instabilities and sound dissipation. As ceramic liners, they must satisfy all requirements respecting mechanical strength and thermal resistance. Design and development of such ceramics concern various aspects like thermal shock resistance, crack behavior, fatigue limit, creep and erosion resistance. The aim of this work is to investigate the mechanical behavior of highly porous sound absorbing ceramics and to predict the brittle damage behavior considering the material microstructure. It studies the applicability of such ceramics as insulation liners for the combustion chambers and gives a clue to further material improvement in terms of mechanical strength. Experiments were performed in this work to characterize the mechanical strengths of a new developed sound absorbing ceramic for the application as ceramic heat shields for the combustion chambers of premixed gas turbines. Compressive tests at both room and high temperature as well as four-point bending tests at room temperature have been carried out. Furthermore, the fits of fracture strengths of the material to the Normal, Weibull and Type I extreme value distributions are investigated. The characterization was then expanded to other physical properties such as porosity, density, thermal conduction coefficients and thermal expansion coefficients. A non-multi-physic but multi-scale approach is applied in this work which predicts the influence of the microstructure on the macroscopic properties. The scale transition method is known as mean-field homogenization method, based on assumed relations between average values of micro-strain and -stress fields in each phase. This homogenization model is based on the Eshelby model and assumes the pores (or rather inclusions) to be ellipsoidal. Influence of the pore density, pore form and pore orientation on the strength of these porous sound absorbing ceramic are studied here. Depending on the loading condition higher strength by higher porosity values is achievable by for example aligning the pores on a desired direction or changing their form from spherical to ellipsoid with high aspect ratios. Furthermore, direct finite element simulations of a representative-volume element (RVE) are also implemented in this work to investigate the pure brittle damage of this sound absorbing ceramic. An effective-stress degradation model has been implemented in a predefined user-subroutine of ABAQUS. It is based on the three dimensional rupture criterion and describes the pure brittle damage under mechanical, thermomechanical, static and quasi-static loadings. Different RVE s have been generated and investigated in terms of damage considering different structural parameters. The present results demonstrate the application potential of these sound absorbing ceramic as liner in terms of mechanical strengths, predict their brittle damage behavior considering the microstructure and provide a base for further material developments and numerical investigations. The applicability of these ceramic to line the combustion chambers in terms of sound absorption is investigated on an experimental set-up at the Faculty of Combustion of the Center of Applied Space Technology and Microgravity (ZARM). The validation of the results from this chapter will be performed on this set-up

Shock Wave Response of Iron-based In Situ Metallic Glass Matrix Composites

The response of amorphous steels to shock wave compression has been explored for the first time. Further, the effect of partial devitrification on the shock response of bulk metallic glasses is examined by conducting experiments on two iron-based in situ metallic glass matrix composites, containing varying amounts of crystalline precipitates, both with initial composition Fe_(49.7)Cr_(17.7)Mn_(1.9)Mo_(7.4)W_(1.6)B_(15.2)C_(3.8)Si_(2.4). The samples, designated SAM2X5-600 and SAM2X5-630, are X-ray amorphous and partially crystalline, respectively, due to differences in sintering parameters during sample preparation. Shock response is determined by making velocity measurements using interferometry techniques at the rear free surface of the samples, which have been subjected to impact from a high-velocity projectile launched from a powder gun. Experiments have yielded results indicating a Hugoniot Elastic Limit (HEL) to be 8.58 ± 0.53 GPa for SAM2X5-600 and 11.76 ± 1.26 GPa for SAM2X5-630. The latter HEL result is higher than elastic limits for any BMG reported in the literature thus far. SAM2X5-600 catastrophically loses post-yield strength whereas SAM2X5-630, while showing some strain-softening, retains strength beyond the HEL. The presence of crystallinity within the amorphous matrix is thus seen to significantly aid in strengthening the material as well as preserving material strength beyond yielding

High-Strain Rate Tensile Characterization Of Graphite Platelet Reinforced Vinyl Ester Based Nanocomposites Using Split-Hopkinson Pressure Bar

The dynamic response of exfoliated graphite nanoplatelet (xGnP) reinforced and carboxyl terminated butadiene nitrile (CTBN) toughened vinyl ester based nanocomposites are characterized under both dynamic tensile and compressive loading. Dynamic direct tensile tests are performed applying the reverse impact Split Hopkinson Pressure Bar (SHPB) technique. The specimen geometry for tensile test is parametrically optimized by Finite Element Analysis (FEA) using ANSYS Mechanical APDL®. Uniform stress distribution within the specimen gage length has been verified using high-speed digital photography. The on-specimen strain gage installation is substituted by a non-contact Laser Occlusion Expansion Gage (LOEG) technique for infinitesimal dynamic tensile strain measurements. Due to very low transmitted pulse signal, an alternative approach based on incident pulse is applied for obtaining the stress-time history. Indirect tensile tests are also performed combining the conventional SHPB technique with Brazilian disk test method for evaluating cylindrical disk specimens. The cylindrical disk specimen is held snugly in between two concave end fixtures attached to the incident and transmission bars. Indirect tensile stress is estimated from the SHPB pulses, and diametrical transverse tensile strain is measured using LOEG. Failure diagnosis using high-speed digital photography validates the viability of utilizing this indirect test method for characterizing the tensile properties of the candidate vinyl ester based nanocomposite system. Also, quasi-static indirect tensile response agrees with previous investigations conducted using the traditional dog-bone specimen in quasi-static direct tensile tests. Investigation of both quasi-static and dynamic indirect tensile test responses show the strain rate effect on the tensile strength and energy absorbing capacity of the candidate materials. Finally, the conventional compressive SHPB tests are performed. It is observed that both strength and energy absorbing capacity of these candidate material systems are distinctively less under dynamic tension than under compressive loading. Nano-reinforcement appears to marginally improve these properties for pure vinyl ester under dynamic tension, although it is found to be detrimental under dynamic compression

The compounding of short fibre reinforced thermoplastic composites

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.It is generally accepted that the mechanical properties of short fibre reinforced thermoplastics do not correspond with the high mechanical properties of fibres used to reinforce them. A study is made into the methods of compounding reinforcing fibres into thermoplastics to produce short fibre reinforced thermoplastics of enhanced properties. The initial method chosen for investigation is the twin screw extrusion compounding process. Variables such as fibre feeding arrangement and extrusion screw design are found to be factors influencing the properties of carbon and glass reinforced nylon 6,6. Use is made of computer programs to predict properties, assess compound quality and estimate fibre-matrix bond strength. Investigations indicate that the presence of reinforcing fibres with enhanced lengths does not result in the predicted property increases. The reasons for this shortfall are believed to lie in unfavourable fibre orientation in injection mouldings and the reduced strain to break of these materials. Short Kevlar reinforced thermoplastics are compounded and their mechanical properties assessed. The reasons for the poor mechanical properties for these materials are identified as a poor bond strength between fibre and matrix, the formation of points of weakness within the fibres by the compounding and moulding processes and the coiled arrangement of fibres present in injection mouldings. A method suitable for the routine assessment of fibre-matrix bond strength is used to examine combinations of fibre and thermoplastic matrix. A comparison is made of the values derived from this method with values calculated from stress-strain curves of injection mouldings. This allows an understanding of the nature of the fibre-matrix bond yielded by compounding and injection moulding steps. A description is given of a novel method designed to overcome the limitations of conventional compounding routes to produce long fibre reinforced injection moulding feedstock. Further work is necessary before this method is a feasible production technique

Program for an improved hypersonic temperature-sensing probe

Under a NASA Dryden-sponsored contract in the mid 1960s, temperatures of up to 2200 C were successfully measured using a fluid oscillator. The current program, although limited in scope, explores the problem areas which must be solved if this technique is to be extended to 10,000 R. The potential for measuring extremely high temperatures, using fluid oscillator techniques, stems from the fact that the measuring element is the fluid itself. The containing structure of the oscillator need not be brought to equilibrium temperature with with the fluid for temperature measurement, provided that a suitable calibration can be arranged. This program concentrated on review of high-temperature material developments since the original program was completed. Other areas of limited study included related pressure instrumentation requirements, dissociation, rarefied gas effects, and analysis of sensor time response

Evolution of microstructure and impact-strength energy in thermally and thermomechanically aged 15-5 PH

Due to its outstanding mechanical resistance and resistance to corrosion, alloy 15-5 PH can be beneficially used for manufacturing aerospace structural parts. Following exposure to intermediate temperature, from300◦–400 ◦C, the alloy embrittles through the decomposition of the martensite into iron-rich and chromium-rich domains.Depending on the ageing time, these domains are either interconnected or unconnected with each other. The embrittlement results in a drastic drop of the impact strength-energy and an increase of the ductile-to-brittle transition temperature. The initial microstructure and mechanical properties can be recovered through a re-homogenization of the distribution of chromium and iron atoms in the material in the case where the decomposition of the matrix is not too pronounced. The application of a stress higher than 60 per cent of the yield strength further enhances the ageing kinetics in the case where the combined effect of temperature and time results in the spinodal decomposition of the martensite