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A unique method was developed to significantly improve the strength of Bi(1−x)Sbx single crystals, the most effective thermoelectric (TE) materials in the temperature range from 100 to 200 K due to their plastic deformation by extrusion. After plastic deformation at room temperature under all-round hydrostatic compression in a liquid medium, n-type Bi–Sb polycrystalline solid solutions show a significant increase in mechanical strength compared to Bi–Sb single crystals in the temperature range from 300 to 80 K. The significantly higher strength of extruded alloys in comparison with Bi–Sb single crystals is associated with the development of numerous grains with a high boundary surface as well as structural defects, such as dislocations, that accumulate at grain boundaries. Significant stability of the structure of extruded samples is achieved due to the uniformity of crystal plastic deformation under all-round hydrostatic compression and the formation of the polycrystalline structure consisting of grains with the orientation of the main crystallographic directions close to the original single crystal. The strengthening of Bi–Sb single crystals after plastic deformation allows for the first time to create workable TE devices that cannot be created on the basis of single crystals that have excellent TE properties, but low strength.

The aim of this study was to investigate the spall propagation mechanism in ball bearing raceways using physics-based models. Spalling is one of the most common types of bearing failures that can lead to catastrophic failure. This research takes a step forward toward developing a prognostic tool for ball bearings. It is first necessary to understand the spall progression process in order to formulate a constitutive law of spall deterioration and to estimate the amount of remaining useful life. Fragment formation in the vicinity of the spall edge was found to consist of surface and sub-surface cracks that eventually coalesce, and a fragment is released from the raceway, based on naturally-developed spalls. Here, we describe a physics-based model, integrating a dynamic model with a finite element one to simulate this process. A continuum damage mechanics (CDM) approach and fracture mechanics tools were embedded into the finite element model to simulate the damage propagation. The formation of cracks in the vicinity of the spall (surface and sub-surface cracks) were studied using this effective stress CDM model, and the propagation of the cracks was examined using two approaches: a fracture mechanics approach and an accumulated inelastic hysteresis energy CDM approach. The latter also predicts the overall process of a single fragment release. The simulation results of the spall propagation models are supported by experimental results of spalls from both laboratory experimental bearings and an in-service Sikorsky CH-53 helicopter swashplate bearing. The results obtained show that the impact of the ball on the spall edge affects the crack propagation and the appearance of the surface and sub-surface cracks. Both release the residual stresses and cause crack propagation until a fragment is released.

Diffusion bonding experiments followed by tensile testing were conducted on cylindrical pairs of AA6061–AA1050 aluminum alloys. The influence of bonding time, atmosphere and surface roughness on the resulting interface strength was studied. Metallurgical characterization was performed to study the quality of the bonded interface for different process conditions, and also to investigate the process of oxide formation on the specimen surface. Finite element analysis of the bonding experiments was used to study the thermo-mechanical fields during the bonding process. Using a cohesive zone approach for modelling the bonded interface, the bond strength for the different process parameters was quantified. The results demonstrate that high bond strength can be obtained even for specimens bonded in an air furnace, provided the surface roughness is low. When the surface roughness increases, specimens bonded in air show a reduction in interface strength, which is not observed for specimens bonded in vacuum. Inspection of the bonded interface suggests that this reduction in interface strength can be attributed to oxidation and pockets of air trapped between the asperities of the contact surface, which hinder diffusion and plastic flow.

This article investigates the spall propagation mechanism for ball bearing raceways by focusing on an experimental investigation of cracks that evolve in the vicinity of the spall edge. Understanding the spall propagation mechanism is an important step towards developing a physics-based prognostic tool for ball bearings. This research reflects an investigation of different spall sizes that propagate naturally both in laboratory experiments and in the field. By using a combined model of a rigid body dynamic model and a finite element model that simulates the rolling element–spall edge interaction, our results shed light on the material behavior (displacements, strains, and stresses) that creates an environment for crack formation and propagation. With the support of the experimental results and the rolling element–spall edge interaction model results, three stages of the mechanism that control fragment release from the raceway were identified. In Stage one, sub-surface cracks appear underneath the spall trailing edge. In Stage two, cracks appear in front of the trailing edge of the spall and, in Stage three, the cracks propagate until a fragment is released from the raceway. These stages were observed in all the tested bearings. In addition, other phenomena that affect the propagation of the cracks and the geometry of the fragment were observed, such as blistering and plastic deformation. We include an explanation of what determines the shape of the fragments.

Polycrystalline PbTe:In films on a polyimide substrate were obtained and investigated. Their structural and transport properties in a wide range of temperatures (10–300 K) were studied. The unique feature of In impurity in PbTe is the stabilization of the Fermi level (pinning effect) that allowed for the preparation polycrystalline films with the same carrier concentration. We found that heat treatment in an argon atmosphere does not change the average grain size and carrier concentration for as-grown films but greatly increases the Hall mobility and the electron mean free path. By comparing the mobility in the bulk and in the film after heat treatment, we extracted the value of the mobility that arises due to scattering at the grain boundary barriers. The ultimate goal of the present study is the development of these films in designing portable uncooled photodetectors for the mid-IR range.

The effects of surface dissolution on dislocation activation in FeSi6.5 steel are quantitatively studied by analyzing the stress relaxation data using the thermal activation theory of dislocation. The stressed FeSi6.5 steel sample in acid solutions (H2SO4 or HCl) exhibits a much higher rate of stress reduction with time compared with that in air or deionized water. As the stress relaxation time is prolonged to 20 min, the relaxation rates are 0.055 MPa·min−1 in water and 0.074, 0.1, 0.11 MPa·min−1 in H2SO4 solutions with pH 4, 3, and 2, respectively. In a NaCl solution, a slight increase in the relaxation rate compared with air was found. Higher acidity (lower pH) of the solution inducing higher stress relaxation rate implies the softening is associated with the anodic dissolution of the surface layer and the accelerated (additional) flow of dislocations. The analyses using the thermal activation theory of dislocation during relaxation reveal the mechanism for the accelerated plastic flow induced by the corrosive medium. The variations of these parameters are related to the relaxation of the stress field of dislocations and the weakening of interaction between slip dislocations and short-range obstacles. The chemomechanical effect, including a reduction in apparent activation energy and a decrease in waiting time for dislocation to obtain sufficient thermal activation energy to cross obstacles, causes an increase in the stress relaxation rate (plastic strain rate). The study confirms that surface dissolution accelerates the plastic flow of metals and supports the view that surface dissolution facilitates dislocation slip. It is helpful to improve the formability of brittle metals.

Formations of germanides in thin films of the Ti-Ge system were investigated by XRD after rapid thermal annealing (RTA) at several temperatures for various times. Phase formation depends on the conditions of the experiments and specifically on the thickness of the Ti film relative to that of the Ge. Considering the equilibrium phase diagram of the Ti-Ge system, if the composition is close the Ge rich side, TiGe2 might be expected to be the first phase to form and the phases present would be TiGe2 and Ge. However this is not the case. If the composition of the constituents is between the compounds of Ti6Ge5 and TiGe2, the first formation can be either one of these, but depends on how close it is to any of these compounds. However Ti6Ge5 is observed always to be the first phase. The presence of Ti6Ge5 and Ti5Ge3 is observed when the composition shifts to a location between these compounds on the phase diagram. Coexistence of Ti and Ti5Ge3 is a possibility when the amount of Ge is below the concentration of the phase Ti5Ge3, namely, when the Ge constituent is completely consumed and excess of Ti is left behind after the reaction. Temperature and time are major parameters that determine the outcome of the reactions between Ti and Ge during RTA and any of these can override the influence of the composition. XRD, SEM, Auger, TEM and resistivity were the experimental tools to study the Ti-Ge system and to evaluate the phases present under a set of experimental conditions.