Laser shock peening without absorbent coating (LSPwC) effect on 3D surface topography and mechanical properties of 6082-T651 Al alloy

The influence of nanosecond laser pulses applied by laser shock peening without absorbent coating (LSPwC) with a Q-switched Nd:YAG laser operating at a wavelength of λ = 1064 nm on 6082-T651 Al alloy has been investigated. The first portion of the present study assesses laser shock peening effect at two pulse densities on three-dimensional (3D) surface topography characteristics. In the second part of the study, the peening effect on surface texture orientation and micro-structure modification, i.e. the effect of surface craters due to plasma and shock waves, were investigated in both longitudinal (L) and transverse (T) directions of the laser-beam movement. In the final portion of the study, the changes of mechanical properties were evaluated with a residual stress profile and Vickers micro-hardness through depth variation in the near surface layer, whereas factorial design with a response surface methodology (RSM) was applied. The surface topographic and micro-structural effect of laser shock peening were characterised with optical microscopy, InfiniteFocus® microscopy and scanning electron microscopy (SEM). Residual stress evaluation based on a hole-drilling integral method confirmed higher compression at the near surface layer (33 μm) in the transverse direction (σmin) of laser-beam movement, i.e. − 407 ± 81 MPa and − 346 ± 124 MPa, after 900 and 2500 pulses/cm2, respectively. Moreover, RSM analysis of micro-hardness through depth distribution confirmed an increase at both pulse densities, whereas LSPwC-generated shock waves showed the impact effect of up to 800 μm below the surface. Furthermore, ANOVA results confirmed the insignificant influence of LSPwC treatment direction on micro-hardness distribution indicating essentially homogeneous conditions, in both L and T directions.

Effect of LSP treatment on the surface topography, friction and wear of Al2024 alloy

OUTLINE: •Introduction •Experimental Setup • Experimental Procedure • Experimental Results - Surface Roughness - Residual Stresses - Friction - Wear - EDX •Conclusions

Fatiga en CFRP: Caracterización y Método Óptico para la Estimación del Daño

El desarrollo de nuevas estructuras aeroespaciales optimizadas, utilizan materiales compuestos, para los componentes críticos y subsistemas, principalmente polímeros reforzados con fibra de carbono (CFRP). Un conocimiento profundo del estado de daño por fatiga de estructuras de CFRP avanzado, es esencial para predecir la vida residual y optimizar los intervalos de inspección estructural, reparaciones y/o sustitución de componentes. Las técnicas actuales se basan principalmente en la medición de cargas estructurales a lo largo de la vida útil de la estructura mediante galgas extensométricas eléctricas. Con esos datos, se estima la vida a fatiga utilizando modelos de acumulación de daño. En la presente tesis, se evalúa la metodología convencional para la estimación de la vida a fatiga de un CFRP aeronáutico. Esta metodología está basada en la regla de acumulación de daño lineal de Palmgren-Miner, y es aplicada para determinar la vida a fatiga de estructuras sometidas a cargas de amplitud variable. Se ha realizado una campaña de ensayos con cargas de amplitud constante para caracterizar un CFRP aeronáutico a fatiga, obteniendo las curvas clásicas S-N, en diferentes relaciones de esfuerzo. Se determinaron los diagramas de vida constante, (CLD), también conocidos como diagramas de Goodman, utilizando redes neuronales artificiales debido a la ausencia de modelos coherentes para materiales compuestos. Se ha caracterizado la degradación de la rigidez debido al daño por fatiga. Se ha ensayado un segundo grupo de probetas con secuencias estandarizadas de cargas de amplitud variable, para obtener la vida a fatiga y la degradación de rigidez en condiciones realistas. Las cargas aplicadas son representativas de misiones de aviones de combate (Falstaff), y de aviones de transporte (Twist). La vida a fatiga de las probetas cicladas con cargas de amplitud variable, se comparó con el índice de daño teórico calculado en base a la regla de acumulación de daño lineal convencional. Los resultados obtenidos muestran predicciones no conservativas. Esta tesis también presenta el estudio y desarrollo, de una nueva técnica de no contacto para evaluar el estado de daño por fatiga de estructuras de CFRP por medio de cambios de los parámetros de rugosidad. La rugosidad superficial se puede medir fácilmente en campo con métodos sin contacto, mediante técnicas ópticas tales como speckle y perfilómetros ópticos. En el presente estudio, se han medido parámetros de rugosidad superficial, y el factor de irregularidad de la superficie, a lo largo de la vida de las probetas cicladas con cargas de amplitud constante y variable, Se ha obtenido una buena tendencia de ajuste al correlacionar la magnitud de la rugosidad y el factor de irregularidad de la superficie con la degradación de la rigidez de las probetas fatigadas. Estos resultados sugieren que los cambios en la rugosidad superficial medida en zonas estratégicas de componentes y estructuras hechas de CFRP, podrían ser indicativas del nivel de daño interno debido a cargas de fatiga. Los resultados también sugieren que el método es independiente del tipo de carga de fatiga que ha causado el daño. Esto último hace que esta técnica de medición sea aplicable como inspección para una amplia gama de estructuras de materiales compuestos, desde tanques presurizados con cargas de amplitud constante, estructuras aeronáuticas como alas y colas de aeronaves cicladas con cargas de amplitud variable, hasta aplicaciones industriales como automoción, entre otros. ABSTRACT New optimized aerospace structures use composite materials, mainly carbon fiber reinforced polymer composite (CFRP), for critical components and subsystems. A strong knowledge of the fatigue state of highly advanced (CFRP) structures is essential to predict the residual life and optimize intervals of structural inspection, repairs, and/or replacements. Current techniques are based mostly on measurement of structural loads throughout the service life by electric strain gauge sensors. These sensors are affected by extreme environmental conditions and by fatigue loads in such a way that the sensors and their systems require exhaustive maintenance throughout system life. In the present thesis, the conventional methodology based on linear damage accumulation rules, applied to determine the fatigue life of structures subjected to variable amplitude loads was evaluated for an aeronautical CFRP. A test program with constant amplitude loads has been performed to obtain the classical S-N curves at different stress ratios. Constant life diagrams, CLDs, where determined by means of Artificial Neural Networks due to the absence of consistent models for composites. The stiffness degradation due to fatigue damage has been characterized for coupons under cyclic tensile loads. A second group of coupons have been tested until failure with a standardized sequence of variable amplitude loads, representative of missions for combat aircraft (Falstaff), and representative of commercial flights (Twist), to obtain the fatigue life and the stiffness degradation under realistic conditions. The fatigue life of the coupons cycled with variable amplitude loads were compared to the theoretical damage index calculated based on the conventional linear damage accumulation rule. The obtained results show non-conservative predictions. This thesis also presents the evaluation of a new non-contact technique to evaluate the fatigue damage state of CFRP structures by means of measuring roughness parameters to evaluate changes in the surface topography. Surface roughness can be measured easily on field with non-contact methods by optical techniques such as speckle and optical perfilometers. In the present study, surface roughness parameters, and the surface irregularity factor, have been measured along the life of the coupons cycled with constant and variable amplitude loads of different magnitude. A good agreement has been obtained when correlating the magnitude of the roughness and the surface irregularity factor with the stiffness degradation. These results suggest that the changes on the surface roughness measured in strategic zones of components and structures made of CFRP, could be indicative of the level of internal damage due to fatigue loads. The results also suggest that the method is independent of the type of fatigue load that have caused the damage. It makes this measurement technique applicable for a wide range of inspections of composite materials structures, from pressurized tanks with constant amplitude loads, to variable amplitude loaded aeronautical structures like wings and empennages, up to automotive and other industrial applications.

Influence of acrylic adhesive viscosity and surface roughness on the properties of adhesive joint

In adhesion, the wetting process depends on three fundamental factors: the surface topography of the adherend, the viscosity of the adhesive, and the surface energy of both. The aim of this paper is to study the influence of viscosity and surface roughness on the wetting and their effect on the bond strength. For this purpose, an acrylic adhesive with different viscosities was synthesized and some properties, such as viscosity and surface tension, were studied before adhesive curing took place. Furthermore, the contact angle and the lap-shear strength were analyzed using aluminum adherends with two different roughnesses. Scanning electron microscopy was used to determine the effect of the viscosity and the roughness on the joint interface. The results showed that the adhesive exhibits an optimal value of viscosity. Below this value, at low viscosities, the low neoprene content produces poor bond strength due to the reduced toughness of the adhesive. Additionally, it also produces a high shrinkage during curing, which leads to the apparition of residual stresses that weakens the interfacial strength. However, once the optimum value, an increase in the viscosity produces a negative effect on the joint strength as a result of an important decrease in the wettability.

Análisis y clasificación de maderas mediante técnicas no invasivas de baja energía

El estudio de materiales, especialmente biológicos, por medios no destructivos está adquiriendo una importancia creciente tanto en las aplicaciones científicas como industriales. Las ventajas económicas de los métodos no destructivos son múltiples. Existen numerosos procedimientos físicos capaces de extraer información detallada de las superficie de la madera con escaso o nulo tratamiento previo y mínima intrusión en el material. Entre los diversos métodos destacan las técnicas ópticas y las acústicas por su gran versatilidad, relativa sencillez y bajo coste. Esta tesis pretende establecer desde la aplicación de principios simples de física, de medición directa y superficial, a través del desarrollo de los algoritmos de decisión mas adecuados basados en la estadística, unas soluciones tecnológicas simples y en esencia, de coste mínimo, para su posible aplicación en la determinación de la especie y los defectos superficiales de la madera de cada muestra tratando, en la medida de lo posible, no alterar su geometría de trabajo. Los análisis desarrollados han sido los tres siguientes: El primer método óptico utiliza las propiedades de la luz dispersada por la superficie de la madera cuando es iluminada por un laser difuso. Esta dispersión produce un moteado luminoso (speckle) cuyas propiedades estadísticas permiten extraer propiedades muy precisas de la estructura tanto microscópica como macroscópica de la madera. El análisis de las propiedades espectrales de la luz laser dispersada genera ciertos patrones mas o menos regulares relacionados con la estructura anatómica, composición, procesado y textura superficial de la madera bajo estudio que ponen de manifiesto características del material o de la calidad de los procesos a los que ha sido sometido. El uso de este tipo de láseres implica también la posibilidad de realizar monitorizaciones de procesos industriales en tiempo real y a distancia sin interferir con otros sensores. La segunda técnica óptica que emplearemos hace uso del estudio estadístico y matemático de las propiedades de las imágenes digitales obtenidas de la superficie de la madera a través de un sistema de scanner de alta resolución. Después de aislar los detalles mas relevantes de las imágenes, diversos algoritmos de clasificacion automatica se encargan de generar bases de datos con las diversas especies de maderas a las que pertenecían las imágenes, junto con los márgenes de error de tales clasificaciones. Una parte fundamental de las herramientas de clasificacion se basa en el estudio preciso de las bandas de color de las diversas maderas. Finalmente, numerosas técnicas acústicas, tales como el análisis de pulsos por impacto acústico, permiten complementar y afinar los resultados obtenidos con los métodos ópticos descritos, identificando estructuras superficiales y profundas en la madera así como patologías o deformaciones, aspectos de especial utilidad en usos de la madera en estructuras. La utilidad de estas técnicas esta mas que demostrada en el campo industrial aun cuando su aplicación carece de la suficiente expansión debido a sus altos costes y falta de normalización de los procesos, lo cual hace que cada análisis no sea comparable con su teórico equivalente de mercado. En la actualidad gran parte de los esfuerzos de investigación tienden a dar por supuesto que la diferenciación entre especies es un mecanismo de reconocimiento propio del ser humano y concentran las tecnologías en la definición de parámetros físicos (módulos de elasticidad, conductividad eléctrica o acústica, etc.), utilizando aparatos muy costosos y en muchos casos complejos en su aplicación de campo. Abstract The study of materials, especially the biological ones, by non-destructive techniques is becoming increasingly important in both scientific and industrial applications. The economic advantages of non-destructive methods are multiple and clear due to the related costs and resources necessaries. There are many physical processes capable of extracting detailed information on the wood surface with little or no previous treatment and minimal intrusion into the material. Among the various methods stand out acoustic and optical techniques for their great versatility, relative simplicity and low cost. This thesis aims to establish from the application of simple principles of physics, surface direct measurement and through the development of the more appropriate decision algorithms based on statistics, a simple technological solutions with the minimum cost for possible application in determining the species and the wood surface defects of each sample. Looking for a reasonable accuracy without altering their work-location or properties is the main objetive. There are three different work lines: Empirical characterization of wood surfaces by means of iterative autocorrelation of laser speckle patterns: A simple and inexpensive method for the qualitative characterization of wood surfaces is presented. it is based on the iterative autocorrelation of laser speckle patterns produced by diffuse laser illumination of the wood surfaces. The method exploits the high spatial frequency content of speckle images. A similar approach with raw conventional photographs taken with ordinary light would be very difficult. A few iterations of the algorithm are necessary, typically three or four, in order to visualize the most important periodic features of the surface. The processed patterns help in the study of surface parameters, to design new scattering models and to classify the wood species. Fractal-based image enhancement techniques inspired by differential interference contrast microscopy: Differential interference contrast microscopy is a very powerful optical technique for microscopic imaging. Inspired by the physics of this type of microscope, we have developed a series of image processing algorithms aimed at the magnification, noise reduction, contrast enhancement and tissue analysis of biological samples. These algorithms use fractal convolution schemes which provide fast and accurate results with a performance comparable to the best present image enhancement algorithms. These techniques can be used as post processing tools for advanced microscopy or as a means to improve the performance of less expensive visualization instruments. Several examples of the use of these algorithms to visualize microscopic images of raw pine wood samples with a simple desktop scanner are provided. Wood species identification using stress-wave analysis in the audible range: Stress-wave analysis is a powerful and flexible technique to study mechanical properties of many materials. We present a simple technique to obtain information about the species of wood samples using stress-wave sounds in the audible range generated by collision with a small pendulum. Stress-wave analysis has been used for flaw detection and quality control for decades, but its use for material identification and classification is less cited in the literature. Accurate wood species identification is a time consuming task for highly trained human experts. For this reason, the development of cost effective techniques for automatic wood classification is a desirable goal. Our proposed approach is fully non-invasive and non-destructive, reducing significantly the cost and complexity of the identification and classification process.

Toward mass production of microtextured microdevices: linking rapid prototyping with microinjection molding

The possibility of manufacturing textured materials and devices, with surface properties controlled from the design stage, instead of being the result of machining processes or chemical attacks, is a key factor for the incorporation of advanced functionalities to a wide set of micro and nanosystems. Recently developed high-precision additive manufacturing technologies, together with the use of fractal models linked to computer-aided design tools, allow for a precise definition and control of final surface properties for a wide set of applications, although the production of larger series based on these resources is still an unsolved challenge. However, rapid prototypes, with controlled surface topography, can be used as original masters for obtaining micromold inserts for final large-scale series manufacture of replicas using microinjection molding. In this study, an original procedure is presented, aimed at connecting rapid prototyping with microinjection molding, for the mass production of two different microtextured microsystems, linked to tissue engineering tasks, using different thermoplastics as ultimate materials.

Thermoelectric assessment of laser peening induced effects on a metallic biomedical Ti6Al4V

Laser peening has recently emerged as a useful technique to overcome detrimental effects associated to another well-known surface modification processes such as shot peening or grit blasting used in the biomedical field. It is worth to notice that besides the primary residual stress effect, thermally induced effects might also cause subtle surface and subsurface microstructural changes that might influence corrosion resistance. Moreover, since maximum loads use to occur at the surface, they could also play a critical role in the fatigue strength. In this work, plates of Ti-6Al-4V alloy of 7 mm in thickness were modified by laser peening without using a sacrificial outer layer. Irradiation by a Q-switched Nd-YAG laser (9.4 ns pulse length) working in fundamental harmonic at 2.8 J/pulse and with water as confining medium was used. Laser pulses with a 1.5 mm diameter at an equivalent overlapping density (EOD) of 5000 cm-2 were applied. Attempts to analyze the global induced effects after laser peening were addressed by using the contacting and non-contacting thermoelectric power (TEP) techniques. It was demonstrated that the thermoelectric method is entirely insensitive to surface topography while it is uniquely sensitive to subtle variations in thermoelectric properties, which are associated with the different material effects induced by different surface modification treatments. These results indicate that the stress-dependence of the thermoelectric power in metals produces sufficient contrast to detect and quantitatively characterize regions under compressive residual stress based on their thermoelectric power contrast with respect to the surrounding intact material. However, further research is needed to better separate residual stress effects from secondary material effects, especially in the case of low-conductivity engineering materials like titanium alloys.

Thresholding Soil Surface Images

Soil erosion is a complex phenomenon involving the detachment and transport of soil particles, storage and runoff of rainwater, and infiltration. The relative magnitude and importance of these processes depends on several factors being one of them surface micro-topography, usually quanti[U+FB01]ed trough soil surface roughness (SSR). SSR greatly affects surface sealing and runoff generation, yet little information is available about the effect of roughness on the spatial distribution of runoff and on flow concentration. The methods commonly used to measure SSR involve measuring point elevation using a pin roughness meter or laser, both of which are labor intensive and expensive. Lately a simple and inexpensive technique based on percentage of shadow in soil surface image has been developed to determine SSR in the field in order to obtain measurement for wide spread application. One of the first steps in this technique is image de-noising and thresholding to estimate the percentage of black pixels in the studied area. In this work, a series of soil surface images have been analyzed applying several de-noising wavelet analysis and thresholding algorithms to study the variation in percentage of shadows and the shadows size distribution

Shadow Analysis of Soil Surface Roughness Compared to the Chain Set Method and Direct Measurement of Micro-relief.

Erosion potential and the effects of tillage can be evaluated from quantitative descriptions of soil surface roughness. The present study therefore aimed to fill the need for a reliable, low-cost and convenient method to measure that parameter. Based on the interpretation of micro-topographic shadows, this new procedure is primarily designed for use in the field after tillage. The principle underlying shadow analysis is the direct relationship between soil surface roughness and the shadows cast by soil structures under fixed sunlight conditions. The results obtained with this method were compared to the statistical indexes used to interpret field readings recorded by a pin meter. The tests were conducted on 4-m2 sandy loam and sandy clay loam plots divided into 1-m2 subplots tilled with three different tools: chisel, tiller and roller. The highly significant correlation between the statistical indexes and shadow analysis results obtained in the laboratory as well as in the field for all the soil?tool combinations proved that both variability (CV) and dispersion (SD) are accommodated by the new method. This procedure simplifies the interpretation of soil surface roughness and shortens the time involved in field operations by a factor ranging from 12 to 20.