Investigation on laser shock peening capability by FE simulation

Laser shock peening is a technique similar to shot peening that imparts compressive residual stresses in materials for improving fatigue resistance. The ability to use a high energy laser pulse to generate shock waves, inducing a compressive residual stress field in metallic materials, has applications in multiple fields such as turbo-machinery, airframe structures, and medical appliances. The transient nature of the LSP phenomenon and the high rate of the laser's dynamic make real time in-situ measurement of laser/material interaction very challenging. For this reason and for the high cost of the experimental tests, reliable analytical methods for predicting detailed effects of LSP are needed to understand the potential of the process. Aim of this work has been the prediction of residual stress field after Laser Peening process by means of Finite Element Modeling. The work has been carried out in the Stress Methods department of Airbus Operations GmbH (Hamburg) and it includes investigation on compressive residual stresses induced by Laser Shock Peening, study on mesh sensitivity, optimization and tuning of the model by using physical and numerical parameters, validation of the model by comparing it with experimental results. The model has been realized with Abaqus/Explicit commercial software starting from considerations done on previous works. FE analyses are “Mesh Sensitive”: by increasing the number of elements and by decreasing their size, the software is able to probe even the details of the real phenomenon. However, these details, could be only an amplification of real phenomenon. For this reason it was necessary to optimize the mesh elements' size and number. A new model has been created with a more fine mesh in the trough thickness direction because it is the most involved in the process deformations. This increment of the global number of elements has been paid with an "in plane" size reduction of the elements far from the peened area in order to avoid too high computational costs. Efficiency and stability of the analyses has been improved by using bulk viscosity coefficients, a merely numerical parameter available in Abaqus/Explicit. A plastic rate sensitivity study has been also carried out and a new set of Johnson Cook's model coefficient has been chosen. These investigations led to a more controllable and reliable model, valid even for more complex geometries. Moreover the study about the material properties highlighted a gap of the model about the simulation of the surface conditions. Modeling of the ablative layer employed during the real process has been used to fill this gap. In the real process ablative layer is a super thin sheet of pure aluminum stuck on the masterpiece. In the simulation it has been simply reproduced as a 100µm layer made by a material with a yield point of 10MPa. All those new settings has been applied to a set of analyses made with different geometry models to verify the robustness of the model. The calibration of the model with the experimental results was based on stress and displacement measurements carried out on the surface and in depth as well. The good correlation between the simulation and experimental tests results proved this model to be reliable.

Development of a novel heat treatment for high performances L-PBF Ti6Al4V alloy: microstructural and mechanical characterization

This work presents the experimental development of a novel heat treatment for a high performance Laser Powder Bed Fusion Ti6Al4V alloy. Additive manufacturing production processes for titanium alloys are particularly of interest in cutting-edge engineering fields, however, high frequency laser induced thermal cycles generate a brittle as built microstructure. For this reason, heat treatments compliant with near net shape components are needed before their homologation and usage. The experimental campaign focused on the development of a multi-step heat treatment leading to a bilamellar microstructure. In fact, according to literature, such a microstructure should be promising in terms of mechanical properties both under static and cyclic loads. The heat treatment development has asked for the preliminary analyses of samples annealed and aged in laboratory, implementing several cycles, differing for what concerns temperatures, times and cooling rates. Such a characterization has been carried out through optical and electron microscopy analyses, image analyses, hardness and tensile tests. As a result, the most suitable thermal cycle has been selected and performed using industrial equipment on mini bending fatigue samples with different surface conditions. The same tests have been performed on a batch of traditionally treated samples, to provide with a comparison. This master thesis activity has finally led to the definition of a heat treatment resulting into a bilamellar microstructure, promising in terms of fatigue performances with respect to the traditionally treated alloy ones. The industrial implementation of such a heat treatment will require further improvements, particularly for what concerns the post annealing water quench, in order to prevent any surface alteration potentially responsible for the fatigue performances drop. Further development of the research may also include push-pull fatigue tests, crack grow propagation and residual stresses analyses.

Modeling and Design of Phase Shifted Full Bridge Isolated DC-DC ZVS Converter with Peak Current Mode Control

Nowadays, there is a boom in the use of electrification. Electric vehicles are gaining interest worldwide due to various factors, including climate and environmental awareness. In this thesis, a step-down isolated power supply for electric tractors is investigated, specifically the phase-shifted full-bridge (PSFB) DC-DC with synchronous rectification and zero-voltage switching (ZVS). This converter was selected for its high-power capacity with high efficiency. A 3500 W PSFB converter with peak current control (PCCM) is designed and modeled in MATLAB. The input voltage range is from 550 V to 820 V and the output voltage range is limited to 9 V to 16 V with a maximum output current of 250 A. All components were commercially designed and selected, including magnetics for the high-frequency transformer and inductors, taking into account loss calculations. Zero voltage switching for the lagging leg is achieved at 13% to 100% load. The proven efficiency of the converter is around 90

Design and Implementation of Single phase 230V to Three Phase Inverter Based on the Embedded System STM-32 Applied to motor control

In the field of Power Electronics, several types of motor control systems have been developed using STM microcontroller and power boards. In both industrial power applications and domestic appliances, power electronic inverters are widely used. Inverters are used to control the torque, speed, and position of the rotor in AC motor drives. An inverter delivers constant-voltage and constant-frequency power in uninterruptible power sources. Because inverter power supplies have a high-power consumption and low transfer efficiency rate, a three-phase sine wave AC power supply was created using the embedded system STM32, which has low power consumption and efficient speed. It has the capacity of output frequency of 50 Hz and the RMS of line voltage. STM32 embedded based Inverter is a power supply that integrates, reduced, and optimized the power electronics application that require hardware system, software, and application solution, including power architecture, techniques, and tools, approaches capable of performance on devices and equipment. Power inverters are currently used and implemented in green energy power system with low energy system such as sensors or microcontroller to perform the operating function of motors and pumps. STM based power inverter is efficient, less cost and reliable. My thesis work was based on STM motor drives and control system which can be implemented in a gas analyser for operating the pumps and motors. It has been widely applied in various engineering sectors due to its ability to respond to adverse structural changes and improved structural reliability. The present research was designed to use STM Inverter board on low power MCU such as NUCLEO with some practical examples such as Blinking LED, and PWM. Then we have implemented a three phase Inverter model with Steval-IPM08B board, which converter single phase 230V AC input to three phase 380 V AC output, the output will be useful for operating the induction motor.

Optical power stabilization of a laser diode for qnd measurement

La realizzazione di stati non classici del campo elettromagnetico e in sistemi di spin è uno stimolo alla ricerca, teorica e sperimentale, da almeno trent'anni. Lo studio di atomi freddi in trappole di dipolo permette di avvicinare questo obbiettivo oltre a offrire la possibilità di effettuare esperimenti su condesati di Bose Einstein di interesse nel campo dell'interferometria atomica. La protezione della coerenza di un sistema macroscopico di spin tramite sistemi di feedback è a sua volta un obbiettivo che potrebbe portare a grandi sviluppi nel campo della metrologia e dell'informazione quantistica. Viene fornita un'introduzione a due tipologie di misura non considerate nei programmi standard di livello universitario: la misura non distruttiva (Quantum Non Demolition-QND) e la misura debole. Entrambe sono sfruttate nell'ambito dell'interazione radiazione materia a pochi fotoni o a pochi atomi (cavity QED e Atom boxes). Una trattazione delle trappole di dipolo per atomi neutri e ai comuni metodi di raffreddamento è necessaria all'introduzione all'esperimento BIARO (acronimo francese Bose Einstein condensate for Atomic Interferometry in a high finesse Optical Resonator), che si occupa di metrologia tramite l'utilizzo di condensati di Bose Einstein e di sistemi di feedback. Viene descritta la progettazione, realizzazione e caratterizzazione di un servo controller per la stabilizzazione della potenza ottica di un laser. Il dispositivo è necessario per la compensazione del ligh shift differenziale indotto da un fascio laser a 1550nm utilizzato per creare una trappola di dipolo su atomi di rubidio. La compensazione gioca un ruolo essenziale nel miglioramento di misure QND necessarie, in uno schema di feedback, per mantenere la coerenza in sistemi collettivi di spin, recentemente realizzato.