Mechanical and microstructural characterization of laser-welded joints of 6013-T4 aluminum alloy

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Efeito da microestrutura nas propriedades mecânicas de aços automotivos dissimilares soldados à laser

Pós-graduação em Engenharia Mecânica - FEG

Estudo da influência do tratamento térmico a laser nas características dos aços avançados de alta resistência dual phase 600 e transformed induced plasticity 750

Pós-graduação em Engenharia Mecânica - FEG

Análise da resistência à fadiga de tubos de aço API 5CT N80 Tipo Q soldados via processo de indução magnética de alta frequência (HFIW)

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Aplicação de projeto de experimento no processo de manufatura de uma bobina de alumínio

TProducts must follow specifications in order to attend demands requested. In terms of rolled aluminum, one of the most significant items for customers is coil thickness. This is because only a tiny variation in thickness might cause a serious problem on customer's manufacturing line. Thereby, this research aims to analyze through design of experiments which factors and how they affect the thickness of aluminum coils. The response variable of the experiment is the thickness of aluminum coil, tensile strenght and yield strenght are the factors of the experiment and trimmers machines were considered as blocking. Data were obtained through tensile tests. The result of the experiment states that, according to the analysis of variance (ANOVA), while there is significant difference between the two levels of tensile strength, there is not any difference between the two levels of yield strength and trimmers machines. The thickness of the aluminum coils with high values of tensile strength tends to be thicker when compared with low values of tensile strength

Aplicação de projeto de experimento no processo de manufatura de uma bobina de alumínio

TProducts must follow specifications in order to attend demands requested. In terms of rolled aluminum, one of the most significant items for customers is coil thickness. This is because only a tiny variation in thickness might cause a serious problem on customer's manufacturing line. Thereby, this research aims to analyze through design of experiments which factors and how they affect the thickness of aluminum coils. The response variable of the experiment is the thickness of aluminum coil, tensile strenght and yield strenght are the factors of the experiment and trimmers machines were considered as blocking. Data were obtained through tensile tests. The result of the experiment states that, according to the analysis of variance (ANOVA), while there is significant difference between the two levels of tensile strength, there is not any difference between the two levels of yield strength and trimmers machines. The thickness of the aluminum coils with high values of tensile strength tends to be thicker when compared with low values of tensile strength

Characterization of a new beta titanium alloy, Ti-12Mo-3Nb, for biomedical applications

In recent years, different beta titanium alloys have been developed for biomedical applications with a combination of mechanical properties including a low Young's modulus, high strength, fatigue resistance and good ductility with excellent corrosion resistance. From this perspective, a new metastable beta titanium Ti-12Mo-3Nb alloy was developed with the replacement of both vanadium and aluminum from the traditional Ti-6Al-4V alloy. This paper presents the microstructure, mechanical properties and corrosion resistance of the Ti-12Mo-3Nb alloy heat-treated at 950 degrees C for 1 h. The material was characterized by X-ray diffraction and by scanning electron microscopy. Tensile tests were carried out at room temperature. Corrosion tests were performed using Ringer's solution at 25 degrees C. The results showed that this alloy could potentially be used for biomedical purposes due to its good mechanical properties and spontaneous passivation. (c) 2011 Elsevier B.V. All rights reserved.

Constitutive models for biodegradable thermoplastic ropes for ligament repair

The concept behind a biodegradable ligament device is to temporarily replace the biomechanical functions of the ruptured ligament, while it progressively regenerates its capacities. However, there is a lack of methods to predict the mechanical behaviour evolution of the biodegradable devices during degradation, which is an important aspect of the project. In this work, a hyper elastic constitutive model will be used to predict the mechanical behaviour of a biodegradable rope made of aliphatic polyesters. A numerical approach using ABAQUS is presented, where the material parameters of the model proposal are automatically updated in correspondence to the degradation time, by means of a script in PYTHON. In this method we also use a User Material subroutine (UMAT) to apply a failure criterion base on the strength that decreases according to a first order differential equation. The parameterization of the material model proposal for different degradation times were achieved by fitting the theoretical curves with the experimental data of tensile tests on fibres. To model all the rope behaviour we had considered one step of homogenisation considering the fibres architectures in an elementary volume. (C) 2012 Elsevier Ltd. All rights reserved.

Experimental analyses of the poly(vinyl chloride) foams' mechanical anisotropic behavior

Assessing a full set of mechanical properties is a rather complicate task in the case of foams, especially if material models must be calibrated with these results. Many issues, for example anisotropy and heterogeneity, influence the mechanical behavior. This article shows through experimental analyses how the microstructure affects different experimental setups and it also quantifies the degree of anisotropy of a poly(vinyl chloride) foam. Monotonic and cyclic experimental tests were carried out using standard compression specimens and non-standard tensile specimens. Results are complemented and compared with the aid of a digital image correlation technique and scanning electron microscopy analyses. Mechanical properties (e.g., elastic and plastic Poisson's ratios) are evaluated for compression and tensile tests, for two different material directions (normal and in-plane). The material is found to be transversely isotropic. Differences in the results of the mechanical properties can be as high as 100%, or even more depending on the technique used and the loading direction. Also, the experimental analyses show how the material's microstructure behavior, like the evolution of the herein identified yield fronts and a spring back phenomenon, can influence the phenomenological response and the failure mechanisms as well as the hardening curves. POLYM. ENG. SCI., 52:2654-2663, 2012. (C) 2012 Society of Plastics Engineers

Chemical composition modification of casting aluminium alloys for engine applications

The research activities were focused on evaluating the effect of Mo addition to mechanical properties and microstructure of A354 aluminium casting alloy. Samples, with increasing amount of Mo, were produced and heat treated. After heat treatment and exposition to high temperatures samples underwent microstructural and chemical analyses, hardness and tensile tests. The collected data led to the optimization of both casting parameters, for obtaining a homogeneous Mo distribution in the alloy, and heat treatment parameters, allowing the formation of Mo based strengthening precipitates stable at high temperature. Microstructural and chemical analyses highlighted how Mo addition in percentage superior to 0.1% wt. can modify the silicon eutectic morphology and hinder the formation of iron based β intermetallics. High temperature exposure curves, instead, showed that after long exposition hardness is slightly influenced by heat treatment while the effect of Mo addition superior to 0,3% is negligible. Tensile tests confirmed that the addition of 0.3%wt Mo induces an increase of about 10% of ultimate tensile strength after high temperature exposition (250°C for 100h) while heat treatments have slight influence on mechanical behaviour. These results could be exploited for developing innovative heat treatment sequence able to reduce residual stresses in castings produced with A354 modified with Mo.

Characterization of thermal and mechanical properties of polypropylene-based composites for fuel cell bipolar plates and development of educational tools in hydrogen and fuel cell technologies

In this project we developed conductive thermoplastic resins by adding varying amounts of three different carbon fillers: carbon black (CB), synthetic graphite (SG) and multi-walled carbon nanotubes (CNT) to a polypropylene matrix for application as fuel cell bipolar plates. This component of fuel cells provides mechanical support to the stack, circulates the gases that participate in the electrochemical reaction within the fuel cell and allows for removal of the excess heat from the system. The materials fabricated in this work were tested to determine their mechanical and thermal properties. These materials were produced by adding varying amounts of single carbon fillers to a polypropylene matrix (2.5 to 15 wt.% Ketjenblack EC-600 JD carbon black, 10 to 80 wt.% Asbury Carbon's Thermocarb TC-300 synthetic graphite, and 2.5 to 15 wt.% of Hyperion Catalysis International's FIBRILTM multi-walled carbon nanotubes) In addition, composite materials containing combinations of these three fillers were produced. The thermal conductivity results showed an increase in both through-plane and in-plane thermal conductivities, with the largest increase observed for synthetic graphite. The Department of Energy (DOE) had previously set a thermal conductivity goal of 20 W/m·K, which was surpassed by formulations containing 75 wt.% and 80 wt.% SG, yielding in-plane thermal conductivity values of 24.4 W/m·K and 33.6 W/m·K, respectively. In addition, composites containing 2.5 wt.% CB, 65 wt.% SG, and 6 wt.% CNT in PP had an in–plane thermal conductivity of 37 W/m·K. Flexural and tensile tests were conducted. All composite formulations exceeded the flexural strength target of 25 MPa set by DOE. The tensile and flexural modulus of the composites increased with higher concentration of carbon fillers. Carbon black and synthetic graphite caused a decrease in the tensile and flexural strengths of the composites. However, carbon nanotubes increased the composite tensile and flexural strengths. Mathematical models were applied to estimate through-plane and in-plane thermal conductivities of single and multiple filler formulations, and tensile modulus of single-filler formulations. For thermal conductivity, Nielsen's model yielded accurate thermal conductivity values when compared to experimental results obtained through the Flash method. For prediction of tensile modulus Nielsen's model yielded the smallest error between the predicted and experimental values. The second part of this project consisted of the development of a curriculum in Fuel Cell and Hydrogen Technologies to address different educational barriers identified by the Department of Energy. By the creation of new courses and enterprise programs in the areas of fuel cells and the use of hydrogen as an energy carrier, we introduced engineering students to the new technologies, policies and challenges present with this alternative energy. Feedback provided by students participating in these courses and enterprise programs indicate positive acceptance of the different educational tools. Results obtained from a survey applied to students after participating in these courses showed an increase in the knowledge and awareness of energy fundamentals, which indicates the modules developed in this project are effective in introducing students to alternative energy sources.

Experimental validation of a mean field model of mineralized collagen fiber arrays at two levels of hierarchy

In the course of this study, stiffness of a fibril array of mineralized collagen fibrils modeled with a mean field method was validated experimentally at site-matched two levels of tissue hierarchy using mineralized turkey leg tendons (MTLT). The applied modeling approaches allowed to model the properties of this unidirectional tissue from nanoscale (mineralized collagen fibrils) to macroscale (mineralized tendon). At the microlevel, the indentation moduli obtained with a mean field homogenization scheme were compared to the experimental ones obtained with microindentation. At the macrolevel, the macroscopic stiffness predicted with micro finite element (μFE) models was compared to the experimental stiffness measured with uniaxial tensile tests. Elastic properties of the elements in μFE models were injected from the mean field model or two-directional microindentations. Quantitatively, the indentation moduli can be properly predicted with the mean-field models. Local stiffness trends within specific tissue morphologies are very weak, suggesting additional factors responsible for the stiffness variations. At macrolevel, the μFE models underestimate the macroscopic stiffness, as compared to tensile tests, but the correlations are strong.

Characterization Of Friction Stir Welded Joints Of Aa 2024-T351 - Native Vs. Treated By Laser Shock Processing

The paper presents a consistent set of results showing the ability of Laser Shock Processing (LSP) in modifying the overall properties of the Friction Stir Welded (FSW) joints made of AA 2024-T351. Based on laser beam intensities above 109 W/cm2 with pulse energies of several Joules and pulses durations of nanoseconds, LSP is able of inducing a compression residual stress field, improving the wear and fatigue resistance by slowing crack propagation and stress corrosion cracking, but also improving the overall behaviour of the structure. After the FSW and LSP procedures are briefly presented, the results of micro-hardness measurements and of transverse tensile tests, together with the corrosion resistance of the native joints vs. LSP treated are discussed. The ability of LSP to generate compressive residual stresses and to improve the behaviour of the FSW joints is underscored.

Flow and fracture behaviour of FV535 steel at different triaxialities, strain rates and temperatures

The new generation jet engines operate at highly demanding working conditions. Such conditions need very precise design which implies an exhaustive study of the engine materials and behaviour in their extreme working conditions. With this purpose, this work intends to describe a numerically-based calibration of the widely-used Johnson–Cook fracture model, as well as its validation through high temperature ballistic impact tests. To do so, a widely-used turbine casing material is studied. This material is the Firth Vickers 535 martensitic stainless steel. Quasi-static tensile tests at various temperatures in a universal testing machine, as well as dynamic tests in a Split Hopkinson Pressure Bar, are carried out at different triaxialities. Using ABAQUS/Standard and LS-DYNA numerical codes, experimental data are matched. This method allows the researcher to obtain critical data of equivalent plastic strain and triaxility, which allows for more precise calibration of the Johnson–Cook fracture model. Such enhancement allows study of the fracture behaviour of the material across its usage temperature range.

Modelo de comportamiento plástico y rotura en aleaciones de solidificación direccional

Esta investigación presenta un modelo de material para aleaciones de solidificación direccional que poseen un comportamiento mecánico transversalmente isótropo. Se han realizado una serie de ensayos de tracción sobre probetas cilíndricas a varias velocidades de deformación y a varias temperaturas sobre la superaleación de base níquel de solidificación direccional MAR-M 247 con objeto de conocer su comportamiento mecánico. Los ensayos se realizaron sobre probetas cilíndricas cuya dirección longitudinal forma 0º y 90º con la de la orientación de crecimiento de los granos. Para representar el comportamiento plástico anisótropo se ha formulado una función de plastificación de forma no cuadrática basada en la transformación lineal de tensores. Con el propósito de simplificar en todo lo posible el modelo se ha considerado un endurecimiento isótropo. Para probar la validez del modelo propuesto se ha implementado el mismo como modelo de material definido por el usuario en el código no lineal de elementos finitos LS-DYNA. In this research a material model for directionally solidified alloys with transversely isotropic mechanic behavior is presented. In order to characterize the mechanical behavior of the Mar-M 247 directionally solidified nickel based superalloy, tensile tests of axisymmetric smooth specimens were performed at various strain rates and temperatures. The specimens were machined making sure that the longitudinal axis of them was forming 0º and 90º with the grain growth orientation. To represent the plastic flow, a non-quadratic anisotropic function based on linear transformation of tensors has been formulated. For the sake of simplicity isotropic strain hardening of the material has been considered. To prove the validity of the model, a material subroutine has been implemented in LS-DYNA non-linear finite element code as a user defined material model.