Measurement of LSP-induced residual stresses and fatigue life on thin-walled aluminium alloys specimens

This thesis work encloses activities carried out in the Laser Center of the Polytechnic University of Madrid and the laboratories of the University of Bologna in Forlì. This thesis focuses on the superficial mechanical treatment for metallic materials called Laser Shock Peening (LSP). This process is a surface enhancement treatment which induces a significant layer of beneficial compressive residual stresses underneath the surface of metal components in order to improve the detrimental effects of the crack growth behavior rate in it. The innovation aspect of this work is the LSP application to specimens with extremely low thickness. In particular, after a bibliographic study and comparison with the main treatments used for the same purposes, this work analyzes the physics of the operation of a laser, its interaction with the surface of the material and the generation of the surface residual stresses which are fundamentals to obtain the LSP benefits. In particular this thesis work regards the application of this treatment to some Al2024-T351 specimens with low thickness. Among the improvements that can be obtained performing this operation, the most important in the aeronautic field is the fatigue life improvement of the treated components. As demonstrated in this work, a well-done LSP treatment can slow down the progress of the defects in the material that could lead to sudden failure of the structure. A part of this thesis is the simulation of this phenomenon using the program AFGROW, with which have been analyzed different geometric configurations of the treatment, verifying which was better for large panels of typical aeronautical interest. The core of the LSP process are the residual stresses that are induced on the material by the interaction with the laser light, these can be simulated with the finite elements but it is essential to verify and measure them experimentally. In the thesis are introduced the main methods for the detection of those stresses, they can be mechanical or by diffraction. In particular, will be described the principles and the detailed realization method of the Hole Drilling measure and an introduction of the X-ray Diffraction; then will be presented the results I obtained with both techniques. In addition to these two measurement techniques will also be introduced Neutron Diffraction method. The last part refers to the experimental tests of the fatigue life of the specimens, with a detailed description of the apparatus and the procedure used from the initial specimen preparation to the fatigue test with the press. Then the obtained results are exposed and discussed.

Experimental characterization and modelling of a servo-pneumatic system for a knee loading apparatus

The new knee test rig developed in University of Bologna used pneumatic cylinder as actuator system. Specific characterization and modelling about the pneumatic cylinder and the related devices are needed in better controlling the test rig. In this thesis, an experimental environment for the related device is set up with data acquisition system using Real-time Windows Target, Simulink, MatLab. Based on the experimental data, a fitted model for the pneumatic cylinder friction is found.

Characterization of thermoelectric commercial modules using a module test system

Il presente lavoro di tesi è stato svolto presso la DTU, Technical University of Denmark, nel Department of Energy Conversion and Storage, Riso Campus. Lo scopo del periodo di soggiorno estero è stato quello di caratterizzare appropriati moduli termoelettrici forniti da aziende del settore, utilizzando un opportuno apparato di caratterizzazione. Quest’ultimo è noto come “module test system” e, nello specifico, è stato fornito dalla PANCO GmbH, azienda anch’essa attiva nel campo delle tecnologie termoelettriche. Partendo da uno studio teorico dei fenomeni fisici interessati (effetto Seebeck per la produzione di potenza termoelettrica), si è cercato in seguito di analizzare le principali caratteristiche, ed elementi, del “module test system”. Successivamente a questa prima fase di analisi, sono stati condotti esperimenti che, con l’aiuto di modelli computazionali implementati attraverso il software Comsol Multiphysics, hanno permesso di studiare l’affidabilità del sistema di caratterizzazione. Infine, una volta acquisite le basi necessarie ad una corretta comprensione dei fenomeni fisici e delle caratteristiche relative alla strumentazione, sono stati analizzati moduli termoelettrici di tipo commerciale. In particolare, sono stati estrapolati dati quali correnti, tensioni, gradienti di temperatura, che hanno permesso di ricavare flussi termici, efficienze, e potenze che caratterizzano il modulo in questione durante le condizioni di funzionamento. I risultati ottenuti sono stati successivamente comparati con dati forniti dal produttore, presenti sul catalogo.