Dynamic mechanical-thermal, microstructural and mechanical analysis of ultra-light polymer-metal composites: influence of forming

A really particular and innovative metal-polymer sandwich material is Hybrix. Hybrix is a product developed and manufactured by Lamera AB, Gothenburg, Sweden. This innovative hybrid material is composed by two relatively thin metal layers if compared to the core thickness. The most used metals are aluminum and stainless steel and are separated by a core of nylon fibres oriented perpendicularly to the metal plates. The core is then completed by adhesive layers applied at the PA66-metal interface that once cured maintain the nylon fibres in position. This special material is very light and formable. Moreover Hybrix, depending on the specific metal which is used, can achieve a good corrosion resistance and it can be cut and punched easily. Hybrix architecture itself provides extremely good bending stiffness, damping properties, insulation capability, etc., which again, of course, change in magnitude depending in the metal alloy which is used, its thickness and core thickness. For these reasons nowadays it shows potential for all the applications which have the above mentioned characteristic as a requirement. Finally Hybrix can be processed with tools used in regular metal sheet industry and can be handled as solid metal sheets. In this master thesis project, pre-formed parts of Hybrix were studied and characterized. Previous work on Hybrix was focused on analyze its market potential and different adhesive to be used in the core. All the tests were carried out on flat unformed specimens. However, in order to have a complete description of this material also the effect of the forming process must be taken into account. Thus the main activities of the present master thesis are the following: Dynamic Mechanical-Thermal Analysis (DMTA) on unformed Hybrix samples of different thickness and on pre-strained Hybrix samples, pure epoxy adhesive samples analysis and finally moisture effects evaluation on Hybrix composite structure.

Evaluation of the microstructural pattern and mechanical behaviour of human metastatic vertebrae

La spina dorsale è uno dei principali siti di sviluppo di metastasi ossee. Queste alterano sia la composizione strutturale che il comportamento meccanico delle vertebre metastatiche, riducendone la resistenza meccanica ed aumentandone il rischio di rottura. Questo studio ha valutato la composizione microstrutturale ed il comportamento meccanico a rottura in specifiche regioni all’interno di vertebre metastatiche. 11 segmenti vertebrali da cadavere, costituiti da una vertebra sana ed una con metastasi (litica, mista o blastica), sono stati testati con carichi graduali di compressione e scansionati con microCT. Le deformazioni interne sono state misurate tramite un algoritmo globale di Digital Volume Correlation (DVC). I risultati dall’analisi microstrutturale hanno mostrato l’ influenza sulla microstruttura delle diverse tipologie di metastasi in corrispondenza della lesione, mentre le caratteristiche microstrutturali nelle regioni intorno alla lesione sono risultate simili a quelle delle vertebre sane. L’analisi delle deformazioni ha inoltre permesso di valutare l’ effetto delle diverse tipologie di metastasi nel compromettere la stabilità spinale. Le vertebre con metastasi litiche hanno raggiunto deformazioni maggiori in corrispondenza della lesione, regione meccanicamente più debole e con una microstruttura maggiormente compromessa a causa della metastasi. Le vertebre con metastasi blastiche hanno raggiunto deformazioni minori nella lesione, regione che ha mostrato una maggiore resistenza meccanica ai carichi, e deformazioni maggiori nelle zone più lontane. Le vertebre con metastasi miste hanno mostrato un comportamento meccanico non univoco, legato alla predominanza di una lesione sull’altra. Infatti, la posizione e la proporzione tra le due lesioni sembra influenzare il comportamento meccanico. I risultati di questo studio, una volta generalizzati, potrebbero portare alla spiegazione delle cause di instabilità meccanica nelle vertebre metastatiche.

Root cause analysis applied to a finite element model's refinement of a negative stiffness structure

Negative Stiffness Structures are mechanical systems that require a decrease in the applied force to generate an increase in displacement. They are structures that possess special characteristics such as snap-through and bi-stability. All of these features make them particularly suitable for different applications, such as shock-absorption, vibration isolation and damping. From this point of view, they have risen awareness of their characteristics and, in order to match them to the application needed, a numerical simulation is of great interest. In this regard, this thesis is a continuation of previous studies in a circular negative stiffness structure and aims at refine the numerical model by presenting a new solution. To that end, an investigation procedure is needed. Amongst all of the methods available, root cause analysis was the chosen one to perform the investigation since it provides a clear view of the problem under analysis and a categorization of all the causes behind it. As a result of the cause-effect analysis, the main causes that have influence on the numerical results were obtained. Once all of the causes were listed, solutions to them were proposed and it led to a new numerical model. The numerical model proposed was of nonlinear type of analysis with hexagonal elements and a hyperelastic material model. The results were analyzed through force-displacement curves, allowing for the visualization of the structure’s energy recovery. When compared to the results obtained from the experimental part, it is evident that the trend is similar and the negative stiffness behaviour is present.

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.