Browsing by Author "Saleh, M"

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    Analysis of compositionally ungraded FGM analogues: Neutron diffraction measurements of residual stress and mechanical testing of pressure sintered Mo-Y2O3 and Mo-Al2O3
    (Karlsruhe Institute of Technology, 2015-05) Saleh, M; Chavara, D; Toppler, K; Alexander, J; Ruys, AJ; Kaveh, K; Luzin, V
    Functionally graded materials (FGMs) are a type of naturally inspired composite materials whose properties (e.g. microstructure, chemical or phase composition) vary over one or more dimensions. The FGMs were first proposed as an advanced engineering material in 1972 and research into application for Biomaterials, Aerospace, Chemical Plants, Mining, and Building material commodities[1, 2] is ever present. Within the nuclear industry FGMs can be engineered to effectively resist corrosion, radiation and are a potential choice for nuclear reactor components e.g. first wall for fusion reactors and fuel pellets. Additionally FGM’s have been proposed as potential plasma facing components (PFC) whereby the PFC would gradually vary from a refractory material (tungsten, plasma face) to a heat sink material (copper, coolant side). In the case of a metal-ceramic FGM, the composite mates the strength and ductility of a metal with the hardness and toughness of a ceramic [3-5]. The authors have sought to elucidate the development of residual stress in FGMs using neutron measurements on the Kowari Strain Scanner, ANSTO for the Mo-Y2O3 and Mo-Al2O3 system. Due to their extreme gradients FGM’s are not optimal for fast neutron measurements due to the high spatial resolution requirements and long measurement times. An alternative approach was employed to examine compositionally ungraded analogues of varying metal-ceramic ratios. All sample were manufactured using constituent powders, mixed and subsequently sintered using a hot press with close monitoring of the sintering curve. Optical microscopy and scanning electron microscopy were used to look at the resultant samples to observe the grain growth and the defect-like cracks attributable to the thermally induced stresses. Relaxation due to micro cracking and micro-fracturing are evaluated in light of the neutron residual stress measurements and mechanical strength measurements of : (a) bending stiffness using a three point bend tests, (b) bulk modulus through GrindoSonic techniques and (c) statistically averaged micro-hardness. Further evaluation of the residual stress is done through comparison between established analytical models, neutron diffraction and preliminary FEA. The major contribution of residual stress are further realised and evaluated in light of the interfacial instabilities present and the appropriate ways to optimise the thermal protection characteristics of a compositional gradient.
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    Analysis of the residual stress and bonding mechanism in the cold spray technique using experimental and numerical methods
    (Elsevier, 2014-08-15) Saleh, M; Luzin, V; Spencer, K
    In the current study, numerical solutions were used to simulate multi-particle deposition in the cold spray (CS) process, and to investigate some of the physical attributes of the deposition process of AA-6061-T6 particles deposited on an AA-6061-T6 substrate. Earlier experimental results are presented, with varying substrate and cladding combination; a subset of these results is analysed using single particle impact simulation, a more traditional approach in simulations of cold spray, and the smooth particle hydrodynamic (SPH) formulation to simulate multi-particle deposition. In a single particle impact simulation, a strong correlation between temperature and plastic deformation of the CS particles during the deposition process was found. The authors were able to correlate the onset of adiabatic shear instability with pronounced reduction in the flow stress with an inversely proportional relation exhibited for both temperature rise and plastic deformation. In the simulation of multiple particle impact, 400 particles, several bulk characteristics were extracted as through-thickness functions: density, equivalent plastic strain and stress profile. Stress profile from the simulation was contrasted against neutron diffraction measurements of residual stress, along with the analytical model of Tsui and Clyne, and is shown to achieve good correlation and providing validation of the results of simulations. Furthermore it was found that these stresses originate from a delicate balance between (a) the strain rate hardening and thermal softening and (b) the shot peening effects induced by the impact of CS particles. Analysis of particle morphologies in the simulation suggests a strong influence of temperature rise at the periphery of CS particles during deposition and dynamic recrystallization with the strong jetting of molten metal allowing for inter particle mixing and substrate adhesion. © 2014, Elsevier B.V.
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    Analysis of the residual stress in ARMOX 500T armour steel and numerical study of the resultant ballistic performance
    (Materials Research Forum LLC, 2016-07-03) Saleh, M; Luzin, V; Kariem, MM; Ruan, D
    Armour steels and their response to ballistic and blast threats have been dutifully studied in light of increased conflict and advances in protection levels. The strength of these quenched and tempered martensitic steels is a result of micro alloying, Ni Cr, and Mn, a combination of hot and cold rolling of the steel and proprietary heat treatments. The resultant hardness and toughness are pronounced and are reflected in the ballistic performance of the steel, although the role of the residual stress (RS) has not been unambiguously confirmed. To elucidate the effects of the RS on ballistic properties a two-step study was performed. Firstly, stress measurements were carried out on ARMOX 500T on the RS diffractometer KOWARI at ANSTO on a 8.3 mm thick plate. Stress components in rolling and transverse directions were calculated. Using the experimentally measured stress profiles as an input, numerical analysis was carried out on the ballistic response of the plate to the 7.62 mm APM2 round. Since numerical modelling inherently require the evaluation of material properties at elevated strain rates, to gauge the impact driven stress-strain response, the material’s responses were derived using experiments utilising quasi-static testing and instrumented high strain rate experiments using the Split Hopkinson Pressure Bar (SHPB) at Swinburne University, Australia. These experimentally determined high strain rate data were incorporated into the Johnson-Cook (J-C) computational models for the flow stress along with literature sourced parameters for the failure model of the plate. Analysis of the two starting conditions, with and without residual stress, allows the authors to draw some conclusion about the role of the residual stress on the ballistic performance of ARMOX 500T armour steel. © 2017 The Authors.
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    Application of a soil model in the numerical analysis of landmine interaction with protective structures
    (DEStech Publications, 2011) Saleh, M; Edwards, L
    Blast analysis using numerical techniques has become increasingly relevant to anticipate the material response of protective structures. Improvised explosive devices and land mines pose a significant threat to the occupants of armoured vehicles, it’s therefore important to increase the accuracy of the numerical analysis by incorporating more sophisticated material models whilst maintaining mathematical tractability. The current research employs an Arbitrary Lagrangian Eulerian (ALE) numerical technique in the hydrocode LS-DYNA for the analysis of the blast event. Further, incorporation of a soil model was carried out for the analysis of a TNT mine blast on a mild steel plate. The primary goals of the research are the implementation of an appropriate soil model and the use of multi-physics finite element analysis to model fluid structure interaction. The agreement with experimental result is very good and the methodology employed captured some important aspects of the blast-structure interaction.
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    Ballistic performance of multi-layered metallic plates impacted by a 7.62-mm APM2 projectile
    (Elsevier, 2011-12-01) Flores-Johnson, EA; Saleh, M; Edwards, L
    This paper presents a numerical investigation of the ballistic performance of monolithic, double- and triple-layered metallic plates made of either steel or aluminium or a combination of these materials, impacted by a 7.62-mm APM2 projectile in the velocity range of 775-950 m/s. Numerical models were developed using the explicit finite element code LS-DYNA. It was found that monolithic plates have a better ballistic performance than that of multi-layered plates made of the same material. This effect diminishes with impact velocity. It was also found that double-layered plates with a thin front plate of aluminium and thick back steel plate exhibit greater resistance than multi-layered steel plates with similar areal density. These predictions indicate that multi-layered targets using different metallic materials should be investigated for improved ballistic performance and weight-savings. Crown Copyright (C) 2011 Published by Elsevier Ltd.
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    A comparative study of two nanoindentation approaches for assessing mechanical properties of ion-irradiated stainless steel
    (The Minerals, Metals & Materials Society, 2020-02-26) Bhattacharyya, D; Saleh, M; Xu, A; Zaidi, Z; Hurt, C; Ionescu, M
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    Composite structures subjected to underwater explosive loadings: a comprehensive review
    (Elsevier, 2021-05-01) Tran, P; Wu, CL; Saleh, M; Bortolan Neto, L; Nguyen-Xuan, H; Ferreira, AJM
    Composites materials and structures are increasingly used to replace conventional materials in civilian and defence-related maritime transportation and infrastructure such as naval vessels, submarines, civilian ships, and oil platforms for its better performance-to-weight ratio and electro-magnetic signature control. However, when subjected to under water explosions (UNDEX), navel composite structures experience highly nonlinear deformations and damages. Such transient deformation phenomena of composites and associated multiscale damages have been a subject of research for many years. This review aims to provide historical and methodological overviews of significant research and contributions in this area over the last 20 years from experimental programs, modelling approaches, post-mortem analysis techniques, analytical approximation and recently emerging area of data-led predictive simulations. UNDEX event is often described by a series of events including (a) the formation of the arriving shock wave, (b) the attenuation of the initial shock wave, (c) development of cavitation due to the reflected tension wave from free surface or the structural obstacles, (d) fluid-structure interaction-induced deformation and associated (e) cavitation coalescence and collapse. Such interconnected dynamic events and their influences on the behaviours of composite structures are subjected to extensive research and therefore summarised in this review work to highlight state-of-the-art field and laboratory-scaled experimental programs including investigations on low temperature and cavitation’s influences. Furthermore, the ongoing increase in the computing power and the development of advanced numerical methods have made it possible for multiscale and multi-physics simulations capturing the complex fluid dynamics associated with UNDEX. Over ten different modelling approaches, hydrocodes and their hybrid combination are summarised and discussed for potential applications. Review on current computational approaches also reveals the shortcomings of predictive modelling due to unavoidable simplifications, empirical assumptions on limited experimental data. Therefore, this work also provides a brief discussion on how data-led modelling approach such as artificial neural networks or deep learning, which is based largely on experimental data, could provide powerful assistance to analytical and deterministic numerical analysis. © 2021 Elsevier Ltd.
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    Deformation behaviour of hexagonal- and circular-patterned Ni single-crystal 2D micro-lattices via in situ micro-tensile testing and computational analysis
    (Springer Nature Limited, 2022-04-22) Xu, A; Saleh, M; Bhattacharyya, D
    The effects of hole shape and orientation on the mechanical properties of micro-scale 2D honeycomb structures, fabricated using a focused ion beam equipment, have been investigated using an in situ micro-mechanical testing machine inside the scanning electron microscope . The material used was single-crystal Ni oriented in the < 100 > direction, with the plane of the 2D micro-lattice having a {001} normal direction. The hole shapes explored were hexagonal and circular, while two different orientations of the hexagonal holes were also compared. One of these orientations had a horizontal arm (designated 0° orientation), while the other had a vertical arm (30° orientation) in each hexagon. The results indicate that there is substantial change in strength and ductility depending on the orientation and shape of the holes with respect to the tensile axis. The samples with 30° oriented hexagonal holes had the lowest strength and highest ductility, while the samples with circular holes showed the greatest yield and tensile strength. The samples with the 0° orientated hexagonal holes had much higher strength and lower ductility than the 30° orientated ones. Moreover, the samples with 0° orientated hexagonal holes, which had a similar hole pattern arrangement to the ones with circular holes, had a similar strength to those of the latter type. Thus, it is apparent from this study that the orientation or arrangement of the holes is more important in determining the properties of the 2D microlattice than the shape of the holes. Finite element simulation of the lattice structures utilised the GTN (Gurson, Tvergaard and Needleman) model to evaluate the failure modes under uniaxial tension. The lattice structure has been shown, in a previous paper by the authors, to exhibit composite like behaviour with strength differences in various parts arising from size effects. These size effect variations were incorporated into the model, and a generalised formulation for the GTN parameters was proposed on the basis of one of the experimental configurations and subsequently applied to the other geometries. The models were in good quantitative agreement with the experimental results with accurate representation of the flows stress and failure modes. © 2022, The Author(s), under exclusive licence to Springer Science Business Media, LLC, part of Springer Nature
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    Evaluation of a hydrocode in modelling NATO threats against steel armour
    (International Symposium on Ballistics, 2010-01-01) Saleh, M; Edwards, L
    Having identified relevant constitutive models and the likely fracture mechanisms, a benchmarking study was undertaken to numerically compute a perforation solution based on the work by Børvik et al [1]. Material strength of ductile metals subjected to high strain phenomena is often described through the Johnson-Cook model [2] or the Zerilli-Armstrong [3] relation; both describe strain rate sensitivity, strain hardening and thermal softening albeit by different means. Phenomenological models like Johnson and Cook’s [2] and the associated fracture criterion by the same authors [4] have been extensively used [1,5-8] across a number of research areas. Whilst useful in capturing the main deformation and failure mechanisms, the author’s note the inherent deficiencies present in these models and resolve to calculating conservative solutions. The study also evaluates the blast response of an elasto-plastic plate using the commercial FEA code LS-DYNA[10]. The peak displacement of each plate is compared to literature [11] through two blast analysis techniques, namely the CONWEP blast code which is embedded in the hydrocode and the computationally expensive, but more accurate, technique of fluid structure coupling via a multi-material ALE formulation. The blast threat is a 6 kg TNT mine modelled using the steel pot test criteria set out by the NATO standard in AEP-55 Vol.2. The ALE formulation is competently described in [12] and we apply it to validate wether it’s applicable for near field blast analysis. We aim to shed some light on the nuances and the problems associated with modelling highly dynamic problems. In the words of Jean Lemaitre and Rodrigue Desmorat [14]: “Very accurate calculations are too often made with a very poor accuracy of the material parameters”
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    Evaluation of soil and fluid structure interaction in blast modelling of the flying plate test
    (Elsevier, 2015-04-15) Saleh, M; Edwards, L
    The influence of the soil properties on the structural integrity of impacted structures is important in light of the increased use of improvised explosive devices (IED’s) and buried explosives. The study deduces material parameters for the Federal Highway Authority (FHWA) soil model in LS-DYNA and comparisons are made with the ConWep and two commonly used soil models. The softening behaviour of semi-cohesive prairie soils due to pore pressure development and the reduction of the cohesion angle are highlighted. The flying plate test is used for validation with very good agreement found, capturing the plate’s kinematic and structural responses. © 2015, Elsevier Ltd.
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    Evaluation of the residual stress in the cold spray technique using smooth particle hydrodynamics modelling and neutron diffraction
    (Trans Tech Publications Ltd, 2014-02) Saleh, M; Luzin, V; Spencer, K
    Cold spray is a material deposition technique in which powdered metals are deposited onto metallic and glass substrates as a means of improving functionality, repair or protection of the underlying substrate. The residual stress that builds up in the material during spraying is closely linked to the coating’s integrity and the bonding mechanism. Neutron diffraction residual stresses measurements were carried out at the OPAL research reactor, ANSTO, using the KOWARI strain scanner to investigate an Al-6061 sample with a fine through-thickness resolution of 0.5 mm. The experimentally determined through thickness stress profiles of the macroscopically thick coatings were used to validate FE calculations made for 100 μm thick coatings using the Smooth Particle Hydrodynamics, SPH, techniques. A pronounced plastic strain gradient was apparent in the tested and modelled samples indicative of the significant residual macro-stresses which develop in the cladding/substrate during the deposition. Around the deposited particle’s periphery (in the jetting region) the temperatures are significant, this lends itself to the presence of grain refinement at the periphery of sprayed particles and the propagation of dynamic recrystallization which is closely coupled with the thermal softening of the particle. © 2014 Trans Tech Publications.
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    Experimental and numerical analysis of reinforced concrete subjected to blast
    (International Association of Protective Structures, 2020-11-23) Saleh, M; Remennikov, A; Antoinat, L; Bortolan Neto, L; Whittaker, A
    Dropped Loads and Accidental Blast in Nuclear Facilities Dropped loads (nuclear flasks) or accidental blast (combustible gases, deuterium/hydrogen release e.g. Fukushima accident) can undermine the structural integrity of containment structures and lead to a transient or sustained radiological release. Current regulatory guidelines and standards employ empirical formulas to calculate local responses of RC walls and slabs of nuclear facilities impacted by projectiles. These formulas were calibrated with data that are no longer available for reassessment and fail to predict complex scenarios. More accurate design equations can be developed by blast and impact analysis of RC panels using novel experimental and numerical techniques.
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    Neutron diffraction measurements of residual stress and mechanical testing of pressure sintered metal-ceramic composite systems
    (Materials Research Forum LLC., 2016-12-22) Toppler, K; Luzin, V; Saleh, M; Ruys, AJ; Kabir, K; Chavara, DT
    Abstract. Functionally graded materials (FGMs) are composite materials which vary in phase composition, microstructure and properties over one or more dimensions. They are a good potential choice for nuclear reactor components as they can be engineered to effectively resist corrosion and radiation damage. In the case of a metal-ceramic FGM, they can mate the strength and ductility of a metal with the hardness and toughness of a ceramic. A series of composite samples of variable metal-ceramic ratios was manufactured by hot uniaxial pressing in cylinders. Bulk uniform samples of a certain composition were manufactured as a more efficient way of studying FGMs without the extreme gradient required in practical applications. Thermally and mechanically generated stresses, inherent in composites, frequently create conditions for micro-cracking development, depending on the material’s micro-structural characteristics and the thermo-mechanical processing route. Bulk stress measurements in the prepared samples were carried out on the Kowari diffractometer on the OPAL reactor at ANSTO. Both phases – metal matrix and ceramic inclusions – were measured in both axial and lateral directions for full characterisation of the composite stress state. When compared against analytical evaluation, experimental results, for some samples, demonstrated significant stress relaxation with micro-cracking being the main suspect. Copyright © 2016 by the author(s)
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    Numerical and analytical modelling of reinforced concrete subjected to large inertial impact
    (Australian Nuclear Science and Technology Organisation, 2018-12-11) Saleh, M; Bortolan Neto, L
    Dropped Loads in Nuclear Facilities Dropped loads can undermine the structural integrity of safety critical components. Relatively high impact velocities can result in significant local damage to the target, such as yielding of materials (bending), buckling or local failure or penetration. In nuclear facilities, a response of this sort may directly or indirectly lead to a transient or sustained radiological release.
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    Numerical FE modelling of occupant injury in soil-vehicle blast interaction
    (DEStech Publications Inc, 2015-03-03) Saleh, M; Smith, R; Shanmugam, DK; Edwards, L
    In ensuring occupant safety, analysis of blasts in soils has become increasingly important in evaluating the influence of the soil properties on the structural integrity of nearby structures. The proliferation of IED’s (improvised explosive devices) and land mines in areas where soil properties are unknown poses a significant threat to the occupants of armoured vehicle. It is therefore important to increase the accuracy of the numerical analysis by incorporating more sophisticated material models whilst maintaining mathematical tractability. The current study aims to incorporate a multi-physics blast FE simulation In LS-DYNA to investigate the interaction of soil blast with an idealised V-Hull vehicle. Using the Hybrid III Anthropomorphic Test Devices model the authors evaluated he dynamic response index (DRIz) and the head injury criterion (HIC), along with the acceleration and forces of the vehicle’s underbody, to assess the suitability of numerical modelling as a tool to optimise hull shape and reduce occupant injury. © The Authors
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    Numerical modelling and computer simulations
    (Woodhead Publishing, 2017) Saleh, M; Edwards, L; Crouch, I
    The development of armour materials and systems is a very expensive business, especially when it involves lengthy ballistic trials. Penetration and perforation events are also highly complex and involve competition between alternative failure mechanisms. The physical conditions within an impact zone also vary, with location, in temperature, strain-rate, strain, stress state and pressure. Numerical modelling and computer simulations help understand these complexities and add value to the design process. This chapter describes some of the underpinning principles by covering the range of computer codes available, the types of processors used, and the breadth of both yield strength models and damage criteria which are employed to describe how an armour material flows, fractures and fails. At the end of the chapter, four worked examples illustrate the choices available when modelling armour/anti-armour interactions. The annexures provide excellent sources of data for the various material models and failure criteria. © 2017, Elsevier.
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    Numerical study of the ballistic performance of multi-layered metallic plates subjected to deformable projectile impact
    (CI-Premier Pte Ltd, 2011-11-16) Flores-Johnson, EA; Saleh, M; Edwards, L
    In this paper a numerical study of the ballistic performance of multi-layered metallic plates is presented. Monolithic, double- and triple-layered plates made of either steel or a combination of steel and aluminium, impacted by a deformable projectile in the velocity range of 750-950 m/s were studied. Finite element models were developed using the explicit code LS-DYNA. It was found that monolithic plates have a better ballistic performance than that of multi-layered plates made with the same material. It was also found that double-layered plates with a thin front plate of aluminium and thick back steel plate exhibit greater resistance than multi-layered steel plates. These predictions indicate that multi-layered targets using different metallic materials should be investigated for improved ballistic performance and weight-savings.
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    Optimisation of numerical modelling for structures subjected to internal blast
    (International Symposium on Military Aspects of Blast and Shock (MABS), 2018-09-23) Saleh, M; Pickerd, V; Yiannakopoulos, G; Brincat, M; Bortolan Neto, L; Mathys, Z; Reid, W
    The design of modern military and naval platforms is often assisted by experiments and computational simulations, that provide relevant insights about material reliability, mechanical performance and design vulnerability to blast loading. An important design consideration for naval platforms is the damage response of structures from internal blast loading which is characterized by high strain rate loading and complex shock and blast wave interactions and reflections. To understand the damage response of structures under this loading condition, scaled experiments coupled with numerical simulations are used to identify (a) the temporal displacement fields using in-situ DIC measurements (b) onset of critical failure in various elements and (c) spatial distribution of internal pressure fields. A methodology for understanding the failure response of structures to internal blast loading is investigated using both scaled experiments and numerical modelling. Experimental data, including pressure, displacement, plastic strain and acceleration measurements, are compared with simulation results to determine modelling accuracy for both elastic and plastic deformation. The multi-scale modelling approach adopts a discretization technique for the structure by way of variations in the material property attributes of: weld material, Heat Affected Zone (HAZ) and parent material. The blast propagation and fluid structure interaction are achieved through an ALE simulation framework and provided insights into the deformation mechanisms exhibited in stiffened containers. Multiple structure configurations are simulated to explore this design space and results are compared with the experimentally observed loading and structural response behaviours. The simulation results, alongside the scaled experiments, provide a robust framework for the prediction of blast response of representative naval structures and allows for their optimization to improve both the subsystem and platform integrity.
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    Rapid mechanical evaluation of quadrangular steel plates subjected to localised blast loadings
    (Elsevier, 2020-03) Bortolan Neto, L; Saleh, M; Pickerd, V; Yiannakopoulos, G; Mathys, Z; Reid, W
    The design of modern military and naval platforms against weapon threats is often assisted by a combination of experimental, analytical and computational simulations. These tools provide relevant insights about material reliability, mechanical performance and platform design vulnerability to support the determination of safety critical aspects, such as response to blast and fragmentation loading. Analytical models are inherently simplified, limiting their ability to accurately model scenarios with complicated geometries and material properties, or highly non-linear loadings. Appropriate experimental and numerical modelling can overcome the limitations of analytical models but also require long lead times and high associated costs. These issues can be a point of concern for projects with strict development schedules, short time-to-solution, and limited resources. Machine learning techniques have proven viable in the development of fast-running models for highly non-linear problems. The present work explores four models based on the Multilayer Perceptron (MLP), a type of Artificial Neural Network (ANN), for assessing the mechanical response of mild steel plates subjected to localised blast loading. Experiments combined with validated Finite Element Analysis (FEA) models provide a hybrid dataset for training ANNs. The resultant dataset is a combination of sparsely populated experimental data with a denser dataset of validated FEA simulations. The final results demonstrate the potential of ANNs to incorporate high strain-rate material response behaviour, such as that from blast loading, into optimised models that can yield timely predictions of structural response. Crown Copyright © 2019 Published by Elsevier Ltd.
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    Rapid vulnerability assessment of naval structures subjected to localised blast
    (Curran Associates, 2017-10-04) Bortolan Neto, L; Saleh, M; Pickerd, V; Yiannakopoulos, G; Mathys, Z; Reid, W
    The development of modern naval vessels is driven by the optimum balance between operational performance, technology restrictions and the costs of ownership. These factors impose limitations on all features of surface ships, including weaponry, structural materials, radar systems, and propulsors. Strategies must be set to identify design features and materials that can enhance the vessels protection in the event of shock loadings e.g. air blast and underwater explosions. Assessment of design solutions is a complicated task due to the large number of unknowns involved. Appropriate computational models and experimental tests can give insights into the expected mechanical behaviour to support the design process. The authors are developing a framework for vulnerability assessment, which includes experimental tests and appropriate finite element (FE) models of representative structural parts subjected to blast loading. This combined approach provides a comprehensive analysis tool but its complexity prevents the quick assessment of the vessel structural vulnerability when various design features and a range of materials are to be considered. To overcome this hurdle, a machine learning model based on Artificial Neural Networks is proposed to identify patterns in numerical and experimental data, yielding timely conclusions about the structural response. © 2017 The Royal Institution of Naval Architects