Properties of mechanically milled and spark plasma sintered Al–15 at.% MgB2 composite materials

Air-atomized pure aluminium powder with 15 at.% MgB₂ was mechanically milled (MMed) by using a vibrational ball mill, and MMed powders were consolidated by spark plasma sintering (SPS) to produce composite materials with high specific strength. Solid-state reactions of MMed powders have been examined by X-ray diffraction (XRD), and mechanical properties of the SPSed materials have been evaluated by hardness measurements and compression tests. Orientation images of microstructures were obtained via the electron backscatter diffraction (EBSD) technique.

The solid-state reactions in the Al–15 at.% MgB₂ composite materials occurred between the MMed powders and process control agent (PCA) after heating at 773–873 K for 24 h. The products of the solid-state reaction were a combination of AlB₂, Al₃BC and spinel MgAl₂O₄. Mechanical milling (MM) processing time and heating temperatures affect the characteristics of those intermetallic compounds. As the result of the solid-state reactions in MMed powders, a hardness increase was observed in MMed powders after heating at 573–873 K for 24 h. The full density was attained for the SPSed materials from 4 h or 8 h MMed powders in the Al–15 at.% MgB₂ composite materials under an applied pressure of 49 MPa at 873 K for 1 h. The microstructure of the SPSed materials fabricated from the MMed powders presented the bimodal aluminium matrix grain structure with the randomly distributions. The Al–15 at.% MgB₂SPSed material from powder MMed for 8 h exhibited the highest compressive 0.2% proof strength of 846 MPa at room temperature.

Determination of plastic yield stress from spherical indentation slope curve

The indentation slope curve from a spherical indentation on elastic-plastic materials is examined. By comparing it with that of an linear elastic material of the same elastic properties, we found that the start point of plastic yielding for an elastic-plastic material can be easily located from the indentation slope curve. Based on this analysis, a simple but effective method is proposed to measure the plastic yield stress of very small samples from a spherical nano-indentation slope curve.

FEA simulation of contact and wear between non-metallic materials for accelerated new product development

The conventional approach ie laboratory life testing to examine the reliability of products takes long time and involves tremendous cost as samples are tested till failures. The accelerated life test (ALT) has recently been used as an alternative method. Although ALT reduces the cost of reliability testing through applying more severe environmental conditions than the normal ones, it is no longer sufficient as it does not describe the process of products’ failure explicitly and it is still highly dependent on physical testing. Consequently, novel practices need to be developed for better understanding of the products’ reliability. A novel Finite Element Analysis (FEA) model incorporating mathematical wear equations is developed in the current work and applied to polymer materials. Wear rate, a key parameter, is calculated by using a combinatorial formula that combines a conventional linear equation with a recently published exponential equation. The local wear is firstly calculated and then integrated over the sliding distance. The FEA simulation works in a loop and performs a series of simulation with updated surface geometries. The simulation is in good agreement with the physical testing result.

Using input-output data in life cycle inventory analysis

The impacts on the environment from human activities are of increasing concern. The need to consider the reduction in energy consumption is of particular interest, especially in the construction and operation of buildings, which accounts for between 30 and 40% of Australia's national energy consumption. Much past and more recent emphasis has been placed on methods for reducing the energy consumed in the operation of buildings. With the energy embodied in these buildings having been shown to account for an equally large proportion of a building's life cycle energy consumption, there is a need to look at ways of reducing the embodied energy of buildings and related products. Life cycle assessment (LCA) is considered to be the most appropriate tool for assessing the life cycle energy consumption of buildings and their products. The life cycle inventory analysis (LCIA) step of a LCA, where an inventory of material and energy inputs is gathered, may currently suffer from several limitations, mainly concerned with the use of incomplete and unreliable data sources and LCIA methods. These traditional methods of LCIA include process-based and input-output-based LCIA. Process-based LCIA uses process specific data, whilst input-output-based LCIA uses data produced from an analysis of the flow of goods and services between sectors of the Australian economy, also known as input-output data. With the incompleteness and unreliability of these two respective methods in mind, hybrid LCIA methods have been developed to minimise the errors associated with traditional LCIA methods, combining both process and input-output data. Hybrid LCIA methods based on process data have shown to be incomplete. Hybrid LCIA methods based on input-output data involve substituting available process data into the input-output model minimising the errors associated with process-based hybrid LCIA methods. However, until now, this LCIA method had not been tested for its level of completeness and reliability. The aim of this study was to assess the reliability and completeness of hybrid life cycle inventory analysis, as applied to the Australian construction industry. A range of case studies were selected in order to apply the input-output-based hybrid LCIA method and evaluate the subsequent results as obtained from each case study. These case studies included buildings: two commercial office buildings, two residential buildings, a recreational building; and building related products: a solar hot water system, a building integrated photovoltaic system and a washing machine. The range of building types and products selected assisted in testing the input-output-based hybrid LCIA method for its applicability across a wide range of product types. The input-output-based hybrid LCIA method was applied to each of the selected case studies in order to obtain their respective embodied energy results. These results were then evaluated with the use of a number of evaluation methods. These evaluation methods included an analysis of the difference between the process-based and input-output-based hybrid LCIA results as an evaluation of the completeness of the process-based LCIA method. The second method of evaluation used was a comparison between equivalent process and input-output values used in the input-output-based hybrid LCIA method as a measure of reliability. It was found that the results from a typical process-based LCIA and process-based hybrid LCIA have a large gap when compared to input-output-based hybrid LCIA results (up to 80%). This gap has shown that the currently available quantity of process data in Australia is insufficient. The comparison between equivalent process-based and input-output-based LCIA values showed that the input-output data does not provide a reliable representation of the equivalent process values, for material energy intensities, material inputs and whole products. Therefore, the use of input-output data to account for inadequate or missing process data is not reliable. However, as there is currently no other method for filling the gaps in traditional process-based LCIA, and as input-output data is considered to be more complete than process data, and the errors may be somewhat lower, using input-output data to fill the gaps in traditional process-based LCIA appears to be better than not using any data at all. The input-output-based hybrid LCIA method evaluated in this study has shown to be the most sophisticated and complete currently available LCIA method for assessing the environmental impacts associated with buildings and building related products. This finding is significant as the construction and operation of buildings accounts for a large proportion of national energy consumption. The use of the input-output-based hybrid LCIA method for products other than those related to the Australian construction industry may be appropriate, especially if the material inputs of the product being assessed are similar to those typically used in the construction industry. The input-output-based hybrid LCIA method has been used to correct some of the errors and limitations associated with previous LCIA methods, without the introduction of any new errors. Improvements in current input-output models are also needed, particularly to account for the inclusion of capital equipment inputs (i.e. the energy required to manufacture the machinery and other equipment used in the production of building materials, products etc.). Although further improvements in the quantity of currently available process data are also needed, this study has shown that with the current available embodied energy data for LCIA, the input-output-based hybrid LCIA appears to provide the most reliable and complete method for use in assessing the environmental impacts of the Australian construction industry.

Lateral strength of zero bond masonry walls subjected to wind loads

Masonry walls are usually laid with the individual masonry units along a course overlapping units in the course below. Commonly, the perpend joints in the course occur above the mid-points of the units below to form a ‘half-bond’ or above a third point to form a ‘third-bond’. The amount of this overlap has a profound influence on the strength of a wall supported on three or four sides, where lateral pressures from wind cause combined vertical and horizontal flexure. Where masonry units are laid with mortar joints, the torsional shear bond resistance between the mortar and overlapping units largely determines the horizontal flexural strength. If there is zero bond strength between units, then the horizontal flexural strength is derived from the frictional resistance to torsion on the overlapping bed-faces of the units. This thesis reports a theoretical and experimental investigation into the frictional properties of overlapping units when subjected to combinations of vertical and horizontal moments and vertical axial compression. These basic properties were used to develop a theory to predict the lateral strength of walls supported on two, three or four sides. A plastic theory of behaviour was confirmed by experiment. The theory was then used to determine maximum unbraced panel sizes for particular boundary conditions. Design charts were developed to determine temporary bracing requirements for panels during construction.