Ex-situ Spectroscopic Characterization of Residual Effects of Thermomechanical Loading on Polyurea

The residual effect of thermally and mechanically loaded polyurea samples was investigated in this study using terahertz time-domain spectroscopy (THz-TDS), operating in the transmission mode. Samples of different thicknesses were submerged in liquid nitrogen and reached cryogenic isothermal condition before equilibrating at room temperature. Another set of samples were extracted from quasi-statically loaded strips. All samples were then interrogated using THz-TDS since terahertz waves exhibit nonionizing interactions with polymers, eliminating the need for any post-loading preparatory steps of the samples. The time-domain terahertz signals were used to extract the optical and electrical properties as a function of sample thickness and loading conditions. The residual effect was prominent in the mechanically loaded samples compared to a nearly negligible presence in thermally loaded ones. On average, the thermally loaded polyurea results were subtle compared to the results of the unloaded samples, whereas samples that were mechanically stretched showed a considerable difference. Spectral analysis reported the frequency-dependent, complex refractive index of virgin and loaded polyurea as a function of thickness and spectral peaks associated with fundamental vibrational modes of the polyurea structure. The spectral peaks were in good agreement with previous research while elucidating the residual effect via the disappearance of three peaks in the low terahertz regime for mechanically loaded samples. In general, the refractive index was dependent on the loading conditions. Terahertz spectroscopy was shown to be a promising tool for future in situ and in operando investigations of field-dependent polymer responses.

Experimental Evaluation of Tension and Shear Responses of Material Discontinuities in Origami-Based Sheet Metal Bending

Origami-based sheet metal (OSM) bending uses the origami concept to form a three-dimensional (3D) structures from a two-dimensional (2D) sheet by a series of bending operation. The OSM bending relies on a material discontinuity (MD) to perform the bending operation where the MDs are subjected to tension and shear load. Even though the OSM bending is a process that is simple, cost-effective, and easy to integrate into mass production, the understanding of the OSM bending mechanics is limiting its wide application. Particularly, the deformation behavior of MDs under tension and shear load remains unknown. Hence, this work investigates the response of MDs to these loads using the standard tension and shear tests. From the tests, critical values for two different ductile fracture criteria (DFC) are determined, and the possibility of a failure occurring in OSM bending is predicted. Results show that the load-bearing capability of the MDs is related to change in the effective cross-section area of a MD. Simple tension and shear tests can provide a simple procedure to predict failure in OSM bending. The impact of self-contact occurred under shear load influences maximum shear force and accuracy of failure prediction.

High Temperature Dynamic Mechanical Properties Characterization of Polymer Coatings via Nanoindentation

Polymer coatings are widely used in industrial applications. The mechanical properties of these polymer coatings are known to vary with temperature and deformation rate. The characterization of the dynamic mechanical properties of these coatings at high temperatures via traditional uniaxial testing is challenging due often to their brittleness and small size. In this paper, the mechanical properties of polymer coatings are reported with emphasis on their dynamic mechanical properties at temperatures up to 280 °C characterized by a dynamic nanoindentation technique with a sharp indenter tip. Nanoindentation was used to characterize the mechanical response with emphasis on dynamic mechanical properties of polymer coatings enclosed in a high-temperature stage. To verify the method, the viscoelastic properties of a reference PET were also characterized by uniaxial cyclic tensile testing which exhibited an excellent agreement with the proposed technique. The proposed nanoindentation method can be applied to other polymer coatings and thin films that are used in applications at high temperatures.

Prediction of the Onset of Failure in Elastomeric Solids with Weld Lines being Represented as Localized Regions of Lower Density

We study the initiation of damage in a polymeric body in which there is a line defect due to the formation of a “weld line” that occurs when two polymer streams join together and then solidify. We show that damage initiates in the region of weakness, namely the “weld line” based on a criterion for damage that was developed earlier in [1]. We also show that if there are other stress concentrators also additionally present, such as a hole, then there is a competition between the stresses induced due to the weakness and the stress as a consequence of the stress concentrator (in this instance a hole). This study adds more credence to the criterion for the initiation of damage that is based completely on knowledge of information at the current configuration of the body, that is, the criterion for damage is not based on the value of quantities that also need information based on a reference configuration such as the stress or strain.

Comparing the Mechanical and Thermal Properties of PLA/Organosolv Lignin Biocomposites Made of Different Biomass for 3D Printing Applications

This work investigates the differences in mechanical and thermal properties of polylactic acid (PLA)/lignin biocomposites made of four different unmodified organosolv lignin materials, three of which were extracted from different woody biomass (maple, oak, and pine) in-house, and one sourced commercially. Filaments made from blends of 30wt% and 40wt% of the in-house lignin and the commercially sourced lignin as fillers in PLA were used to 3D-print experimental test samples using fused filament fabrication (FFF) process. Statistically significant differences were observed in the mechanical properties based on tension testing and Izod impact testing, while differences in thermal properties based on differential scanning calorimetry (DSC) and thermogravimetric (TGA) analysis were less significant. Test samples with 30wt% lignin had tensile strengths that were higher than those of 40wt% lignin. Among the three in-house extracted lignin from the woody biomass resources, maple-based composites consistently yielded the highest tensile strengths while oak-based materials yielded the highest stiffness in tension testing and the most stability in impact resistance. The pine-based materials showed the most decline in strengths between 30wt% and 40wt% lignin loadings. The commercially obtained lignin at 30wt% and pine-based lignin at 40wt% yielded much higher percent elongations at failure than all other materials. This study demonstrates the influence of lignin biomass resources and their concentrations on the properties and performances of 3D printed specimens.

Mechanical And Microstructural Performance Evaluation Of Diffusion Bonded Alloy 800H For Very High Temperature Nuclear Service

Very high temperature reactors (VHTRs) are planned to be operated between 550 to 950°C, and demand a thermally efficient intermediate heat exchanger (IHX) in the heat transport system (HTS). The current technological development of compact heat exchangers (CHXs) for VHTRs is at the ‘proof of concept’ level. A significant development in the CHX technologies is essential for the VHTRs to be efficient, cost-effective, and safe. CHXs have very high thermal efficiency and compactness, making them a prime candidate for IHXs in VHTRs. Photochemically etched plates with the desired channel pattern are stacked and diffusion bonded to fabricate CHXs. All plates are compressed at an elevated temperature over a specified period in the diffusion bonding process, promoting atomic diffusion and grain growth across bond surfaces resulting in a monolithic block. The diffusion bonding process changes the base metal properties, which are unknown for Alloy 800H, a candidate alloy for CHX construction. Hence, developing mechanical response data and understanding failure mechanisms of diffusion bonded Alloy 800H at elevated temperatures is a key step for advancing the technology of IHXs in VHTRs. The ultimate goal of this study is to develop ASME BPVC Section III, Division 5 design rules for CHXs in nuclear service. Towards this goal, mechanical performance and microstructures of diffusion bonded Alloy 800H is investigated through a series of tensile, fatigue, creep, and creep-fatigue tests at temperatures 550 to 760°C. The test results, failure mechanisms, and microstructures of diffusion bonded Alloy 800H is scrutinized and presented.

Protective and Thermophysical Characteristics of Plasma-Electrolytic Coatings on the Ultra-Light Magnesium Alloy

Magnesium alloys are now widely used for various purposes due to their unique properties despite the significant disadvantage associated with low corrosion resistance. The plasma-electrolytic oxidation (PEO), which allows the formation of ceramic coatings on the surface of magnesium alloys, is the most advanced and effective method for their protection. But firstly, PEO process of magnesium alloys has some difficulties, and secondly, PEO coatings affect the thermophysical characteristics of the modified materials, in particular they reduce thermal diffusivity. The presented work is devoted to the development of the technological parameters for formation of protective coating on the ultra-light alloy Mg-8Li-1Al-0.6Ce-0.3Y by the PEO method. The results analyses of electrolytes acidity and specific electrical conductivity before and after PEO process and also investigation data of the coatings structure and surface morphology are presented. An integral assessment of the ability of thermal diffusivity and corrosion resistance of the modified alloy was made. Studying of protective and thermophysical characteristics of the obtained coating showed that it provides a sufficiently high corrosion protection, despite the relatively small thickness, and the presence of pores and slightly (not more than 5%) reduces the thermal diffusivity of the magnesium ultra-light alloy.

Nondestructive Photoelastic and Machine Learning Characterization of Surface Cracks and Prediction of Weibull Parameters for Photovoltaic Silicon Wafers

A nondestructive photoelastic method is presented for characterizing surface microcracks in monocrystalline silicon wafers, calculating the strength of the wafers, and predicting Weibull parameters under various loading conditions. Defects are first classified from through thickness infrared photoelastic images using a support vector machine learning algorithm. Characteristic wafer strength is shown to vary with the angle of applied uniaxial tensile load, showing greater strength when loaded perpendicular to the direction of wire motion than when loaded along the direction of wire motion. Observed variations in characteristic strength and Weibull shape modulus with applied tensile loading direction stem from the distribution of crack orientations and the bulk stress field acting on the microcracks. Using this method it is possible to improve manufacturing processes for silicon wafers by rapidly, accurately, and nondestructively characterizing large batches in an automated way.

Effect of Synthesis Procedure on Particle Dispersion and Hardness of Al- Sic Functionally Graded Metal Matrix Composite

Fabrication of Functionally Graded Metal Matrix Composites (FGMMC) especially with high ceramic reinforcement's volume fraction is highly challenging. Depending on the processing technique and process parameters various defects may arise. This research aims to find the best procedure to make FGMMCs with the highest quality and minimum cost. A new method is proposed that incorporates lost-foam and melt infiltration with semicentrifugal casting to produce FGMMC. Experiments were performed to in-situ fabricate 6061-Aluminum alloy reinforced with gradient distributed Silicon carbide particles (Al/SiC FGMMC). Effect of SiC %, Al pouring temperature and rotational speed on the fabricated specimens hardness and reinforcement gradient were investigated using design of experiments and regression analysis. Results reveal the optimum procedure and process settings based on desired properties/gradient required. Mathematical model formulated captures the effect of these process parameters on process cost, and cost of poor quality. Improper selection of those parameters may lead to extensive losses due cost of poor quality which is 12 times higher than the material cost. The proposed manufacturing process proved satisfactory in ensuring proper dispersion. A desirability function can by used to determine the process parameters and volume fraction that minimizes the defects and gives superior properties for a specific application.

Characterization of the Formability of High-Purity Polycrystalline Niobium Sheets for SRF Applications

The forming limit diagram of high-purity niobium sheets used for the manufacturing of superconducting radiofrequency (SRF) cavities is presented. The Marciniak (in-plane) test was used with niobium blanks with a thickness of 1 mm and blank carriers of annealed oxygen-free electronic copper. A high formability was measured, with an approximate true major strain at necking for plane-strain of 0.441. The high formability of high-purity niobium is likely caused by its high strain rate sensitivity of 0.112. Plastic strain anisotropies (r-values) of 1.66, 1.00, and 2.30 were measured in the 0°, 45°, and 90° directions. However, stress–strain curves at a nominal strain rate of ~10−3 s−1 showed similar mechanical properties in the three directions. Theoretical calculations of the forming limit curves (FLCs) were conducted using an analytical two-zone model. The obtained results indicate that the anisotropy and strain rate sensitivity of niobium affect its formability. The model was used to investigate the influence of strain rate on strains at necking. The obtained results suggest that the use of high-speed sheet forming should further increase the formability of niobium.