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Graphical abstract, Highlights • High-speed imaging captured de-agglomeration and dispersion of oxide aggregates. • De-agglomeration occurred from both bulk and surface of the aggregate. • Floating microbubble cluster drones produced fine suspension of loose agglomerates. • Ultrasonic capillary effect promoted de-agglomeration of particles from within. • Subharmonic and low order ultra-harmonic bubble emissions induced oxide breakage., Ultrasonic de-agglomeration and dispersion of oxides is important for a range of applications. In particular, in liquid metal, this is one of the ways to produce metal-matrix composites reinforced with micron and nano sized particles. The associated mechanism through which the de-agglomeration occurs has, however, only been conceptualized theoretically and not yet been validated with experimental observations. In this paper, the influence of ultrasonic cavitation on SiO2 and MgO agglomerates (commonly found in lightweight alloys as reinforcements) with individual particle sizes ranging between 0.5 and 10 μm was observed for the first time in-situ using high-speed imaging. Owing to the opacity of liquid metals, a de-agglomeration imaging experiment was carried out in de-ionised water with sequences captured at frame rates up to 50 kfps. In-situ observations were further accompanied by synchronised acoustic measurements using an advanced calibrated cavitometer, to reveal the effect of pressure amplitude arising from oscillating microbubbles on oxide de-agglomeration. Results showed that ultrasound-induced microbubble clusters pulsating chaotically, were predominantly responsible for the breakage and dispersion of oxide agglomerates. Such oscillating cavitation clusters were seen to capture the floating agglomerates resulting in their immediate disintegration. De-agglomeration of oxides occurred from both the surface and within the bulk of the aggregate. Microbubble clusters oscillating with associated emission frequencies at the subharmonic, 1st harmonic and low order ultra-harmonics of the driving frequency were deemed responsible for the breakage of the agglomerates.

Graphical abstract, Highlights • Mechanical properties of extracted intermetallics determined using a nano-indenter. • High speed imaging captures shock waves breaking intermetallics. • Shock waves seen to promote crack growth leading to fragmentation. • In-situ shock wave pressure measurements obtained using a fibre optic hydrophone. • Subharmonic emissions generate repetitive bending and fracture of intermetallics., One of the main applications of ultrasonic melt treatment is the grain refinement of aluminium alloys. Among several suggested mechanisms, the fragmentation of primary intermetallics by acoustic cavitation is regarded as very efficient. However, the physical process causing this fragmentation has received little attention and is not yet well understood. In this study, we evaluate the mechanical properties of primary Al3Zr intermetallics by nano-indentation experiments and correlate those with in-situ high-speed imaging (of up to 1 Mfps) of their fragmentation process by laser-induced cavitation (single bubble) and by acoustic cavitation (cloud of bubbles) in water. Intermetallic crystals were chemically extracted from an Al-3 wt% Zr alloy matrix. Mechanical properties such as hardness, elastic modulus and fracture toughness of the extracted intermetallics were determined using a geometrically fixed Berkovich nano-diamond and cube corner indenter, under ambient temperature conditions. The studied crystals were then exposed to the two cavitation conditions mentioned. Results demonstrated for the first time that the governing fragmentation mechanism of the studied intermetallics was due to the emitted shock waves from the collapsing bubbles. The fragmentation caused by a single bubble collapse was found to be almost instantaneous. On the other hand, sono-fragmentation studies revealed that the intermetallic crystal initially underwent low cycle fatigue loading, followed by catastrophic brittle failure due to propagating shock waves. The observed fragmentation mechanism was supported by fracture mechanics and pressure measurements using a calibrated fibre optic hydrophone. Results showed that the acoustic pressures produced from shock wave emissions in the case of a single bubble collapse, and responsible for instantaneous fragmentation of the intermetallics, were in the range of 20–40 MPa. Whereas, the shock pressure generated from the acoustic cavitation cloud collapses surged up to 1.6 MPa inducing fatigue stresses within the crystal leading to eventual fragmentation.

The objective of this paper is to model and analyse the dynamic response of an automotive lamp assembly. Modern automotive lamp assemblies have complex geometry and are composed of different parts made of polymer materials. As part of design verification, automotive lamp assemblies are subjected to accelerated random vibration tests to assess their integrity over a life-time exposure to mechanical vibration loading. Understanding the dynamic behaviour of the lamp is crucial in the numerical evaluation of the fatigue life. Dynamic analysis involves characterising the modal and harmonic behaviours. In this work, numerical modal properties and harmonic responses were validated using experimental testing. The numerical analysis was carried out using the ANSYS finite element analysis (FEA) software. Experimental modal properties including mode shapes and corresponding frequencies were determined using Polytec PSV-500 Xtra laser scanning head at a frequency range of 10 to 1000Hz. The experimental harmonic transmissibility responses of all the components of the lamp assembly were determined using a vibration shaker. The experimental and numerical mode shapes and responding frequencies obtained in the analyses compared well thus validating the numerical modal model. Furthermore, the mode shapes showed that the lamp assembly was mostly vibrating in bending, therefore subsequent analysis should take this into account. Harmonic response validation showed that the first few numerical resonant frequencies, that dominate the response, compared well with experimental results.

© The Authors, 2020. Ultrasonic cavitation melt treatment (UST) of aluminium alloys has received considerable attention in the metal industry due to its simple and effective processing response. The refined primary intermetallic phases formed in the treated alloys during controlled solidification, govern alloy structural and mechanical properties for applications in the automotive and aerospace industries. Since the UST is performed close to the liquidus temperatures of the alloys, understanding the refinement mechanism of the primary intermetallic phases has been beset by difficulties in imaging and handling of liquid metals. In this paper, the sonofragmentation behaviour of primary intermetallic Al3Zr crystals extracted from the matrix of an Al-3 wt% Zr alloy and fixed on a solid substrate was investigated. The intermetallics were exposed to cavitation action in deionized water at 24 kHz of ultrasound frequency. The fragmentation mechanism from the nearby collapsing cavitation bubbles was studied with in-situ high speed imaging. Results revealed that the main fragmentation mechanism is associated with the propagation of shock wave emissions from the collapsing bubble clouds in the vicinity of the crystal. The mechanical properties of the Al3Zr phase determined previously were used for the fracture analysis. It was found that an Al3Zr intermetallic undergoes low cycle fatigue fracture due to the continuous interaction with the shock wave pressure. The magnitude of the resulting shear stress that leads to intermetallic fragmentation was found to be in the range of 0.6 – 1 MPa.

The estimation of crack growth under variable amplitude loading is complex due to interaction effects such as plasticity, crack tip blunting, residual stresses, crack tip closure and crack tip branching. Crack closure has been identified to be one of the main interaction effects. In order to study the effect of crack closure the authors have previously carried out experimental testing to obtain more accurate measurements of crack opening and closure (Aguilar-Espinosa, 2009, Aguilar-Espinosa et al., 2013). They have also developed two dimensional plane stress Finite Element models utilising high mesh density whilst maintaining the ability to measure crack growth over long crack lengths (Aguilar Espinosa et al. 2017). This initial work has been extended in this paper to examine the effects of single and block overloads and random spectrum loading on crack growth. The crack length distance that is affected by overloads and underloads measured experimentally and predicted numerically are shown to be very close when using cyclic hardening material properties and kinematic hardening. In addition the comparison of experimental and numerical crack growth versus crack length graphs shows good correlation of the crack growth acceleration and retardation after the applied overload which has not been seen previously. These comparisons seem to be a very useful tool to validate numerical models.

There is increasing demand for effective and efficient lightweight structures because of global environmental and resource sustainability concerns. Adhesive bonding has been adopted in many assembly arrangements because of its relative reduction of stress concentration in joints compared to mechanical fasteners. Functionally graded bonded joints presents even greater potentials for reduction of stress concentrations and the tailoring of stress distribution as may be desired in an adhesive layer. This capability provides opportunity for the design of high performance tailored structural assemblies. Although some encouraging analysis and experimental work have been carried out on the development of functionally graded joints, its wide application is still to be realised. This paper reviews the work that has been carried out so far on the method, in terms of analysis, fabrication, experimental testing and application. It also reflects on outstanding issues that need to be resolved in order for wider application to be feasible.

Ceramics have extensively been used for ballistic protection in the last decades. The combination of their mechanical properties makes them very interesting for armouring. Indeed, they exhibit a high hardness, large compression strength, high stiffness and low density. Ceramic armouring plates are commonly manufactured through a sintering process, where ceramic powders are pressed at high temperatures. This manufacturing process tends to limit the size and shape of components and imparts high costs. On the other hand, moulding using a polymer matrix composite provides an alternative process for developing lower cost parts whilst accommodating increased complexity of geometry and size.However, the mechanical behaviour of such a material is not completely known and depends on multiple design parameters: the mechanical properties of the phases, their volume fraction, the size and spatial distributions of the particles, and the adhesion between the components. The objective of the thesis is to evaluate the influence of the main morphological parameters on the overall mechanical properties, emphasising the influence of the particle/matrix adhesion. To do so, both numerical and experimental multiscale analyses of the material under quasi-static and dynamic loadings were carried out.More precisely, static and dynamic properties of the particle-reinforced composite have been determined for different combinations of the design variables. In particular, attention has been dedicated to the particle/matrix decohesion mechanism. Cohesive zone models (CZM) and Finite Fracture Mechanics (FFM) approaches were used to model this phenomenon and a strong effect of the particle size on debonding was observed., Les matériaux céramiques présentent généralement des propriétés mécaniques très intéressantes pour la réalisation de blindages. Ce sont des matériaux très durs et pourtant légers. Les plaques de blindages en céramique sont classiquement mises en forme par pressage à haute température de poudres, ce qui limite la taille et la forme des réalisations tout en impliquant un coût élevé. Une alternative pour produire ces pièces est le moulage d’un composite constitué de particules de céramiques dans une matrice époxy. Ce procédé permet de réduire le coût des pièces tout en autorisant des géométries plus complexes et des dimensions plus importantes.Le comportement mécanique de ce type de matériau dépend de multiples paramètres de conception : propriétés mécaniques des constituants (matrice polymère et particules céramiques), proportion volumique des deux phases, taille et distribution spatiale des particules ou encore l’adhésion entre les constituants. L’objectif de la thèse est d’évaluer l’influence de ces paramètres sur les propriétés d’usage du matériau. Pour ce faire, une analyse multi-échelle du matériau sous sollicitations quasi-statique et dynamique est réalisée.Plus précisément, les propriétés statiques et dynamiques du composite à renforts particulaires ont été déterminées pour différentes combinaisons de ces paramètres de conception. En particulier, le mécanisme de décohésion particule/matrice a été spécifiquement étudié. Les approches de Modèles de Zone Cohésive (CZM) et de Mécanique de la Rupture Finie (FFM) ont été utilisées pour modéliser ce phénomène et un fort effet de taille des particules a été observé.