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The European Parliament and Council has defined a mandatory specific emission target of 95 g CO2/km by 2020 for passenger cars. Vehicle weight is a significant factor contributing to fuel consumption. Reducing the weight of the vehicle can be one promising option for decreasing CO2 emissions, which becomes a top priority for the automotive industry. In this research, two approaches were used to address the need. One involved developing structural parts using fibre reinforced plastics (FRP), and the other involved designing and developing FRP–metal hybrid laminates, which were constructed by reinforcing FRP locally to the metal surface. Existing joining techniques such as riveting, bolting, adhesive joining, ultrasonic welding, and flow drill joining techniques require additional processing steps to perform the joining, which could considerably increase processing time, cost, and energy expenditure. The present work describes a method to join FRP and metals using the adhesion strength of the investigated polymers. The developed FRP–metal hybrid laminates combine the advantages of metal and FRP together. Steel hot-stamping is known to yield very high strength. Fibre reinforced plastic–metal hybrid laminates were developed using hot stamped steels to transfer their superior mechanical properties to the final structure. To utilize the complete lightweight potential of thermoset and thermoplastic polymers, FRPs and FRP–metal hybrid laminates were developed using both the polymers. Along with this increased demand for FRP structures, there is growing interest in a repair technique in the automotive industry. The second objective of this thesis consists of designing and developing a new repair technique, which regains the strength and stiffness properties of the damaged part. The existing scarf repair technique is not suitable for thin laminates, which have limited access to the damaged area. Perforation damages were introduced into the FRP structures using a low-velocity impact load. A modified injection repair technique is used to repair these damaged FRP structures. Non-destructive techniques were utilized to understand the damage and the effectiveness of the repair.
The powder metallurgically produced beta titanium alloys (traditional PM beta Ti-alloys) have long been plagued by high impurities contamination. For binder-based powder technologies, they originate from the sintering atmosphere, the debinding processes and the starting powders. In general, a normal carbon residual of binder-based powder technologies is capable of incurring the formation of aligned TiCx particles along beta grain boundaries (GB-TiCx) in most classes of beta Ti-alloys. Whereas, oxygen atoms are likely to deteriorate the ductility of PM Ti alloys by promoting the formation of diverse brittle phases and/or altering the deformation modes. Such materials exhibiting rather low toughness to strain ratios are not an option for critical structural applications, where catastrophic damage is completely unacceptable.
In this study, biotolerant metastable beta Ti-20Nb-10Zr alloys, containing a certain amount of carbon, oxygen residuals originated from materials processing and consequently 0.5 vol.% in situ synthesized TiCx particles, were fabricated via metal-injection-molding (MIM). With varying yttrium (Y) addition, the effects of Y-induced oxygen scavenging, beta-grain refinement and porosity increment on tensile properties were systematically investigated. To scavenge oxygen from the beta Ti-matrix, the Y elemental powder with a maximum particle size of 15 µm (e.g. <12 µm or 1200 mesh) is more appropriate than the commonly used <45 µm (i.e. 325 mesh) sized powder or larger ones and without significant detrimental effect on the as-sintered density of beta Ti-alloys.
A novel toughening strategy was proposed by regulating TiCx precipitation evolution and resultantly adjusting particles distribution pattern. Synchrotron radiation identified that two separate TiCx precipitation-type reactions occurred at the beta phase region and the alpha/beta region. In a narrow temperature range between these two precipitation reactions, dissolution of carbides was observed just below alpha/beta transus. Y addition can postpone TiCx precipitation. On the basis of those mechanisms, adjusting TiCx particle distribution was proposed for the first time, specifically a combination of yttrium addition (Y) and carbide spheroidization reprecipitation annealing (CSRA). As a result, aligned GB-TiCx particles were adjusted to dispersed intragranular TiCx particles. An apparent toughening effect (≈ 113% increment reaching elongation = 8.3%) was achieved after TiCx redistribution, while non-optimally aligned TiCx pattern seriously limited tensile toughness of materials. Here, the mechanisms of TiCx redistribution behavior and its toughening are elucidated systematically.
Titanium and its alloys have been widely used as implant biomaterials due to their suitable combination of mechanical properties and biological compatibilities. At present, about 70-80% of implants are made of metallic biomaterials. Compared with magnesium alloys, stainless steel and cobalt alloys, titanium alloys have a higher specific strength, high corrosion resistance, and excellent biocompatibility. With research, Ti-Nb biomedical titanium alloys have been constantly developed. In the Ti-Nb alloy, the amount of Nb is usually from 16% to 42% (wt.%) which is about 10% to 30% (at.%). As reported, Mn as a trace element to the human body has the potential to be used in bio-materials. Therefore, this study aims at the partial replacement of Nb by Mn to reduce the costs, without deteriorating the mechanical properties. Moreover, it must be ensured good biocompatibility and corrosion resistance. This is the first investigated on Ti-Mn-Nb ternary alloys.
In this work, According to β single-phase field, Ti-xMn-yNb (x=4, 10, 16; y=2, 8, 14, at.%) alloys (arc-melted) have been fabricated. The Ti-Mn-Nb alloys are investigated by optical microscopy (OM), X-ray diffraction (XRD), hardness test, transmission electron microscopy (TEM) and mechanical testing. By screening study on alloy, Ti-10Mn-14Nb (at.%) (Ti-10Mn-23.7Nb (wt.%)) is the optimal alloy with tensile strength (760 MPa) and elongation (10.5%). After that, the Metal Injection Moulding (MIM) is used to prepare Ti-Mn-Nb alloys. The MIM method can greatly reduce the processing cost. MIM Ti-xMn-yNb (x=3, 4, 6; y=1, 2, 4, at.%), Ti-4Mn-14Nb and Ti-10Mn-14Nb alloys are fabricated. Among them, a very good combination of mechanical properties is achieved for MIM processed Ti-4Mn-2Nb (at.%) (Ti-4.5Mn-3.8Nb (wt.%)), namely a YS of 642 MPa, UTS of 725 MPa and high ductility of 16% elongation to fracture. With further investigations, when the yttrium content is 0.1% (at.%), the tensile strength of Ti-4Mn-2Nb-0.1Y (at.%) (Ti-4.5Mn-3.8Nb-0.18Y (wt.%)) is increased to 785 MPa while elongation of 12.9%. These mechanical properties already exceed Ti-6Al-4V (ASTM F2885 Grade 5 undensified).
In the in vitro evaluation, in comparison with MIM pure titanium, human osteoblasts MG63 adhered as well and proliferated on the surface of MIM Ti-Mn-Nb specimens. In the supernatant after cell culture, the Ti-Mn-Nb alloy shows similar osmolality and pH value results as MIM pure titanium. By LDH assay and DNA isolation, the MIM Ti-Mn-Nb alloys are not found to be toxic to MG63 cells.
In the study of corrosion resistance in Hanks’ balanced salt solution (HBSS) at 37 °C, the corrosion current densities as well as the impedance of MIM Ti-Mn-Nb alloys are all better than those of MIM pure titanium and even better than those of MIM Ti-6Al-4V alloy.