Improved micro-contact resistance model that considers material deformation, electron transport and thin film characteristics

This paper reports on an improved analytic model forpredicting micro-contact resistance needed for designing microelectro-mechanical systems (MEMS) switches. The originalmodel had two primary considerations: 1) contact materialdeformation (i.e. elastic, plastic, or elastic-plastic) and 2) effectivecontact area radius. The model also assumed that individual aspotswere close together and that their interactions weredependent on each other which led to using the single effective aspotcontact area model. This single effective area model wasused to determine specific electron transport regions (i.e. ballistic,quasi-ballistic, or diffusive) by comparing the effective radius andthe mean free path of an electron. Using this model required thatmicro-switch contact materials be deposited, during devicefabrication, with processes ensuring low surface roughness values(i.e. sputtered films). Sputtered thin film electric contacts,however, do not behave like bulk materials and the effects of thinfilm contacts and spreading resistance must be considered. Theimproved micro-contact resistance model accounts for the twoprimary considerations above, as well as, using thin film,sputtered, electric contact

An investigation of fatigue crack growth acceleration

The problem of fatigue crack growth acceleration was investigated in crack propagation studies and endurance testing. The study was driven by the needs of designers and researchers alike, to provide a better understanding of the mechanisms associated with accelerated growth, and recommendations on the use of Miner's rule to calculate fatigue life under variable amplitude loading. The study was conducted on S355 structural steel and 6082 T6 aluminium alloy using centre-crack tension (CCT) specimens, with and without additional welding, and longitudinal fillet welded specimens. Crack growth rates under simple sequence loading and more complex variable amplitude (VA) loading, all cycling down from fixed tensile stress levels, were determined using optical or direct current potential' drop methods and scanning electron microscope examination of fracture surface striations. Under simple loading sequences, comprising two magnitudes of stress range, the presence of tensile underloads resulted in accelerated growth rates compared with those based on constant amplitude (CA) loading. Various possible mechanisms to explain crack growth acceleration and factors that might influence it, notably crack closure and welding residual stress, were evaluated. The most promising outcome came from finite element analysis (FEA) of the crack tip stress and strain. This showed that whereas under CA loading the material near the crack tip cycled about zero mean stress, the mean stress was tensile after the application of a tensile underload, thus resulting in a higher crack growth rate. Fatigue endurance testing of welded joints performed under the same types of loading confirmed that Miner's rule overestimated the actual lives, consistent with the occurrence of acceleration. Thus, it was concluded that modification of the principle and application of Miner's rule is required to allow for stress interactions that cause crack growth acceleration. Preliminary design recommendations were made

The influence of surface residual stress on fatigue crack growth.

Residual stress exists in most structures and although it has been recognised for a long time, its complex mechanism and characteristics are still being intensively studied. Residual stress can be stratified into damaging residual stress and beneficial residual stress. Surface tensile residual stresses are generally known to reduce the mechanical properties of materials while compressive residual stresses improve the fatigue performance of components. This Ph.D. thesis reports the analytical and experimental work conducted to investigate both the damaging and beneficial effects of residual stress on fatigue crack growth in structural components. The detrimental effect of tensile residual stresses is studied through large scale fatigue testing of T-butt welded plates fabricated from High Strength Steels (HSS). Despite the growing use of HSSs in the offshore industry, the fatigue performance and corrosion resistance of welded joints made from such steels are still not clear. Due to their complex metallurgy and relatively poor weldability, there is still a lack of understanding of the residual stresses that arise from the welding process. This study involved modification and development conducted on a variable amplitude (VA) load-time sequence generator for the investigation of long life fatigue performance of HSS. Emphasis was given to the generation of a stationary load-time history and numerous analyses were presented to demonstrate the importance of the long term statistical nature of the load-time sequence on fatigue testing. Fatigue test results obtained were extensively compared with previous HSS corrosion fatigue studies. The effect of tensile residual stress on fatigue crack growth was investigated using a SIF weight function-based fatigue crack growth model. Two newly developed preferential cold working techniques termed stitch cold rolling and stitch shot peening were explored to investigate the beneficial effect of surface compressive residual stress on fatigue crack growth in mild steel plates. One of the main objectives of this study was to control the fatigue crack shape by the manipulation of surface residual stress fields. The stitch cold rolling technique was implemented using a custom-built cold rolling jig. The feasibility of preferential cold working techniques was further investigated by the fatigue testing of stitch shot peened specimens. Both experimental programmes yielded unprecedented fatigue crack growth results. A residual stress monitoring programme was conducted to study the residual stress relaxation behaviour under cyclic loading. The experimental test results enabled the investigation of SIF solutions in non-uniform stress fields. A novel fatigue crack growth evolution model, which takes into account residual stress relaxation effects, was developed using the powerful SIF weight function methods

Validation of in situ applicable measuring techniques for analysis of the water adsorption by stone

As the water adsorbing behaviour (WAB) of stone is a key factor for most degradation processes, its analysis is a decisive aspect when monitoring deterioration and past conservation treatments, or when selecting a proper conservation treatment. In this study the performance of various non-destructive methods for measuring the WAB are compared, with the focus on the effect of the variable factors of the methods caused by their specific design. The methods under study are the contact-sponge method (CSM), the Karsten tube (KT) and the Mirowski pipe (MIR). Their performance is compared with the standardized capillary rise method (CR) and the results are analysed in relation to the open porosity of different lithotypes. Furthermore the effect of practical encumbrances which could limit the application of these methods was valuated. It was found that KT and CSM have complementary fields of investigation, where CSM is capable of measuring the initial water uptake of less porous materials with a high precision, while KT was found commodious for measuring longer contact times for more porous lithotypes. MIR showed too many discommodities, leading to unreliable results. To adequately compare the results of the different methods, the size of the contact area appears to be the most influential factor, whereas the contact material and pressure on the surface do not indicate a significant influence on the results. The study of these factors is currently being extended by visualization of the water adsorption process via X-ray and neutron radiography in combination with physico-mathematical models describing the WAB

The design and development of a light-weight aluminium semi-trailer

A dissertation submitted to the Faculty of Engineering, University of the Witwatersrand, Johannesburg, in fuldlment of the requirements for the degree of Master of Science in Engineering Johannesburg, 1991With increasing competition in the commercial vehicle industry, future vehicle designs need to be able to carry greater payloads within the bounds of existing legislation. Increasing the payload efficiency of transport vehicles involves two main areas: a. Optomizing the size and mass distribution of the vehicle for the purpose intended. b. Keeping the tare mass as low as possible through efficient design and the use of lighter and stronger materials. [Abbreviated Abstract. Open document to view full version]MT201

Fracture, Fatigue, and Structural Integrity of Metallic Materials and Components Undergoing Random or Variable Amplitude Loadings

Most metallic components and structures are subjected, in service, to random or variable amplitude loadings. There are many examples: vehicles subjected to loadings and vibrations caused by road irregularity and engine, structures exposed to wind, off-shore platforms undergoing wave-loadings, and so on. Just like constant amplitude loadings, random and variable amplitude loadings can make fatigue cracks initiate and propagate, even up to catastrophic failures. Engineers faced with the problem of estimating the structural integrity and the fatigue strength of metallic structures, or their propensity to fracture, usually make use of theoretical, numerical, or experimental approaches. This reprint collects a series of recent scientific contributions aimed at providing an up-to-date overview of approaches and case studies—theoretical, numerical or experimental—on several topics in the field of fracture, fatigue strength, and the structural integrity of metallic components subjected to random or variable amplitude loadings