Concrete develops strength rapidly after mixing and is highly influenced by temperature and curing process. The material characteristics and the rate of property development, along with the exposure conditions influences volume change mechanisms in concrete, and the cracking propensity of the mixtures. Furthermore, the structure geometry (due to restraint as well as the surface area-to-volume ratio) also influences shrinkage and cracking. Thus, goal of this research is to better understand and predict shrinkage cracking in concrete slab systems under different curing conditions. In this research, different concrete mixtures are evaluated on their propensity to shrink based on free shrinkage and restrained shrinkage tests.Furthermore, from the data obtained from restrained ring test, a casted slab is measured for shrinkage. Effects of different orientation of restraints are studied and compared to better understand the shrinking behavior of the concrete mixtures. The results show that the maximum shrinkage is near the edges of the slab and decreases towards the center. Shrinkage near the edges with no restraint is found out to be more than the shrinkage towards the edges with restraining effects.

Alkali activated mine tailing-slag blends and mine tailing-cement blends containing mine tailings as the major binder constituent are evaluated for their setting time behavior, reactivity properties, flow characteristics, and compressive strengths. Liquid sodium silicate and sodium hydroxide are used as the activator solution. The effects of varying alkali oxide-to-powder ratio (n value) and silicon oxide-to-alkali oxide ratio (Ms value) is explored. The reactivity of all blends prepared in this study is studied using an isothermal calorimeter. Mine tailing-cement blends show a higher initial heat release peak than mine tailing-slag blends, whereas their cumulative heat release is comparable for higher n values of 0.050 to 0.100. Compressive strength tests and rheological studies were done for the refined blends selected based on setting time criterion. Setting times and compressive strengths are found to depend significantly on the activator parameters and binder compositions, allowing fine-tuning of the mix proportion parameters based on the intended end applications. The compressive strength of the selected mine tailing-slag blends and mine tailing-cement blends are in the range of 7-40 MPa and 4-11 MPa, respectively. Higher compressive strength is generally achieved at lower Ms and higher n values for mine tailing-slag blends, while a higher Ms yields better compressive strength in the case of mine tailing-cement blends. Rheological studies indicate a decrease in yield stress and viscosity with increase in the replacement ratio, while a higher activator concentration increase both. Oscillatory shear studies were used to evaluate the storage modulus and loss modulus of the mine tailing binders. The paste is seen to exhibit a more elastic behavior at n values of 0.05 and 0.075, however the viscous behavior is seen to dominate at higher n value of 0.1 at similar replacement ratios and Ms value. A higher Ms value is also seen to increase the onset point of the drop in both the storage and loss modulus of the pastes. The studied also investigated the potential use of mine tailing blends for coating applications. The pastes with higher alkalinity showed a lesser crack percentage, with a 10% slag replacement ratio having a better performance compared to 20% and 30% slag replacement ratios. Overall, the study showed that the activation parameters and mine tailings replacement level have a significant influence on the properties of both mine tailing-slag binders and mine tailing-cement binders, thereby allowing selection of suitable mix design for the desired end application, allowing a sustainable approach to dispose the mine tailings waste

High-temperature mechanical behaviors of metal alloys and underlying microstructural variations responsible for such behaviors are essential areas of interest for many industries, particularly for applications such as jet engines. Anisotropic grain structures, change of preferred grain orientation, and other transformations of grains occur both during metal powder bed fusion additive manufacturing processes, due to variation of thermal gradient and cooling rates, and afterward during different thermomechanical loads, which parts experience in their specific applications, could also impact its mechanical properties both at room and high temperatures. In this study, an in-depth analysis of how different microstructural features, such as crystallographic texture, grain size, grain boundary misorientation angles, and inherent defects, as byproducts of electron beam powder bed fusion (EB-PBF) AM process, impact its anisotropic mechanical behaviors and softening behaviors due to interacting mechanisms. Mechanical testing is conducted for EB-PBF Ti6Al4V parts made at different build orientations up to 600°C temperature. Microstructural analysis using electron backscattered diffraction (EBSD) is conducted on samples before and after mechanical testing to understand the interacting impact that temperature and mechanical load have on the activation of certain mechanisms. The vertical samples showed larger grain sizes, with an average of 6.6 µm, a lower average misorientation angle, and subsequently lower strength values than the other two horizontal samples. Among the three strong preferred grain orientations of the α phases, <1 1 2 ̅ 1> and <1 1 2 ̅ 0> were dominant in horizontally built samples, whereas the <0 0 0 1> was dominant in vertically built samples. Thus, strong microstructural variation, as observed among different EB-PBF Ti6Al4V samples, mainly resulted in anisotropic behaviors. Furthermore, alpha grain showed a significant increase in average grain size for all samples with the increasing test temperature, especially from 400°C to 600°C, indicating grain growth and coarsening as potential softening mechanisms along with temperature-induced possible dislocation motion. The severity of internal and external defects on fatigue strength has been evaluated non-destructively using quantitative methods, i.e., Murakami’s square root of area parameter model and Basquin’s model, and the external surface defects were rendered to be more critical as potential crack initiation sites.

Composite materials have gained interest in the aerospace, mechanical and civil engineering industries due to their desirable properties - high specific strength and modulus, and superior resistance to fatigue. Design engineers greatly benefit from a reliable predictive tool that can calculate the deformations, strains, and stresses of composites under uniaxial and multiaxial states of loading including damage and failure predictions. Obtaining this information from (laboratory) experimental testing is costly, time consuming, and sometimes, impractical. On the other hand, numerical modeling of composite materials provides a tool (virtual testing) that can be used as a supplemental and an alternate procedure to obtain data that either cannot be readily obtained via experiments or is not possible with the currently available experimental setup. In this study, a unidirectional composite (Toray T800-F3900) is modeled at the constituent level using repeated unit cells (RUC) so as to obtain homogenized response all the way from the unloaded state up until failure (defined as complete loss of load carrying capacity). The RUC-based model is first calibrated and validated against the principal material direction laboratory tests involving unidirectional loading states. Subsequently, the models are subjected to multi-directional states of loading to generate a point cloud failure data under in-plane and out-of-plane biaxial loading conditions. Failure surfaces thus generated are plotted and compared against analytical failure theories. Results indicate that the developed process and framework can be used to generate a reliable failure prediction procedure that can possibly be used for a variety of composite systems.

Layer-wise extrusion of soft-solid like cement pastes and mortars is commonly used in 3D printing of concrete. Rheological and mechanical characterization of the printable binder for on-demand flow and subsequent structuration is a critical challenge. This research is an effort to understand the mechanics of cementitious binders as soft solids in the fresh state, towards establishing material-process relationships to enhance print quality. This study introduces 3D printable binders developed based on rotational and capillary rheology test parameters, and establish the direct influence of packing coefficients, geometric ratio, slip velocities, and critical print velocities on the extrudate quality. The ratio of packing fraction to the square of average particle diameter (0.01-0.02), and equivalent microstructural index (5-20) were suitable for printing, and were directly related to the cohesion and extrusional yield stress of the material. In fact, steady state pressure for printing (30-40 kPa) is proportional to the extrusional yield stress, and increases with the geometric ratio (0-60) and print velocity (5-50 mm/s). Higher print velocities results in higher wall shear stresses and was exponentially related to the slip layer thickness (estimated between 1-5μ), while the addition of superplasticizers improve the slip layer thickness and the extrudate flow. However, the steady state pressure and printer capacity limits the maximum print velocity while the deadzone length limits the minimum velocity allowable (critical velocity regime) for printing. The evolution of buildability with time for the fresh state mortars was characterized with digital image correlation using compressive strain and strain rate in printed layers. The fresh state characteristics (interlayer and interfilamentous) and process parameters (layer height and fiber dimensions) influence the hardened mechanical properties. A lower layer height generally improves the mechanical properties and slight addition of fiber (up to 0.3% by volume) results in a 15-30% increase in the mechanical properties. 3D scanning and point-cloud analysis was also used to assess the geometric tolerance of a print based on mean error distances, print accuracy index, and layer-wise percent overlap. The research output will contribute to a synergistic material-process design and development of test methods for printability in the context of 3D printing of concrete.

There is a high demand for customized designs of various types of cement-based materials in order to address specific purposes in the construction field. These demands stem from the need to optimize the cementitious matrix properties and reinforcement choices, especially in high reliability, durability, and performance applications that include infrastructure, energy production, commercial buildings, and may ultimately be extended to low risk/high volume applications such as residential applications. The typical tools required to guide practicing engineers should be based on optimization algorithms that require highly efficient capacity and design alternatives and optimal computational tools. The general case of flexural design of members is an important aspect of design of structural members which can be extended to a variety of applications that include various cross-sections such as rectangular, W-sections, channels, angles, and T sections. The model utilized the simplified linear constitutive response of cement-based composite in compression and tension and extends into a two-segment elastic-plastic, strain softening, hardening, tension-stiffening, and a multi-segment system. The generalized parametric model proposed uses a dimensionless system in the stress-strain materials diagram to formulate piecewise equations for an equilibrium of internal stresses and obtains strain distributions for the closed-form solution of neutral axis location. This would allow for the computation of piecewise moment-curvature response. The number of linear residual stress implemented is flexible to a user to maintain a robust response. In the present approach bilinear, trilinear, and quad-linear models are addressed and a procedure for incorporating additional segments is presented. Moreover, a closed-form solution of moment-curvature can be solved and employed in calculating load-deflection response. The model is adaptable for various types of fiber-reinforced and textile reinforced concrete (FRC, TRC, UHPC, AAC, and Reinforced Concrete). The extensions to cover continuous fiber reinforcement such as textile reinforced concrete (TRC, FRCM) strengthening and repair are addressed. The theoretical model is extended to incorporate the hybrid design (HRC) with continuous rebar with FRC to increase the ductility and ultimate moment capacity. HRC extends the performance of the fiber system to incorporate residual capacity into a serviceability-based design that reduced the reliance on the design based on the limit state. The design chart for HRC and as well as conventional RC has been generated for practicing engineering applications. Results are compared to a large array of data from experimental results conducted at the ASU structural lab facilities and other published literature.

Ultra High Performance (UHP) cementitious binders are a class of cement-based materials with high strength and ductility, designed for use in precast bridge connections, bridge superstructures, high load-bearing structural members like columns, and in structural repair and strengthening. This dissertation aims to elucidate the chemo-mechanical relationships in complex UHP binders to facilitate better microstructure-based design of these materials and develop machine learning (ML) models to predict their scale-relevant properties from microstructural information.To establish the connection between micromechanical properties and constitutive materials, nanoindentation and scanning electron microscopy experiments are performed on several cementitious pastes. Following Bayesian statistical clustering, mixed reaction products with scattered nanomechanical properties are observed, attributable to the low degree of reaction of the constituent particles, enhanced particle packing, and very low water-to-binder ratio of UHP binders. Relating the phase chemistry to the micromechanical properties, the chemical intensity ratios of Ca/Si and Al/Si are found to be important parameters influencing the incorporation of Al into the C-S-H gel.
ML algorithms for classification of cementitious phases are found to require only the intensities of Ca, Si, and Al as inputs to generate accurate predictions for more homogeneous cement pastes. When applied to more complex UHP systems, the overlapping chemical intensities in the three dominant phases – Ultra High Stiffness (UHS), unreacted cementitious replacements, and clinker – led to ML models misidentifying these three phases. Similarly, a reduced amount of data available on the hard and stiff UHS phases prevents accurate ML regression predictions of the microstructural phase stiffness using only chemical information. The use of generic virtual two-phase microstructures coupled with finite element analysis is also adopted to train MLs to predict composite mechanical properties. This approach applied to three different representations of composite materials produces accurate predictions, thus providing an avenue for image-based microstructural characterization of multi-phase composites such UHP binders. This thesis provides insights into the microstructure of the complex, heterogeneous UHP binders and the utilization of big-data methods such as ML to predict their properties. These results are expected to provide means for rational, first-principles design of UHP mixtures.

There has been a renewed interest to understand the degradation mechanism of concrete under radiation as many nuclear reactors are reaching their expiration date. Much of the information on the degradation mechanism of concrete under radiation comes from the experiments, which are carried out on very small specimens. With the advent of finite element analysis, a numerical predictive tool is desired that can predict the extent of damage in the nuclear concrete structure.

A mesoscale micro-structural framework is proposed in Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element framework which represents the first step in this direction. As part of the framework, a coupled creep damage algorithm was developed and implemented in MOOSE. The algorithm considers creep through rheological models, while damage evolves exponentially as a function of elastic strain and creep strain. A characteristic length is introduced in the formulation such that the energy release rate associated with each element remains the same to avoid vanishing energy dissipation with mesh refinement. A creep damage parameter quantifies the effect of creep strain on the damage that was calibrated using three-point bending experiments with varying rates of loading.

The creep damage model was also validated with restrained ring shrinkage tests on cementitious materials containing compliant/stiff inclusions subjected to variable drying conditions. The simulation approach explicitly considers: (i) moisture diffusion driven differential shrinkage along the depth of the specimen (ii) viscoelastic response of aging cementitious materials (iii) isotropic damage model with Rankine′s failure initiation criterion, and (iv) random distribution of tensile strengths of individual finite elements.

The model was finally validated with experimental results on neutron-irradiated concrete. The simulation approach considers: (i) coupled hygro-thermal model to predict the temperature and humidity profile inside the specimen (ii) radiation-induced volumetric expansion of aggregates (RIVE) (iii) thermal, shrinkage and creep effects based on the temperature and humidity profile and (iv) isotropic damage model with Rankine’s criterion to determine failure initiation.

This research summarizes the characterization of the constituent materials of a unidirectional composite for use in a finite element model. Specifically the T800s-F3900 composite from Toray Composites, Seattle, WA. Testing was carried out on cured polymer matrix provided by the manufacturer and single fiber specimen. The material model chosen for the polymer matrix was MAT 187 (Semi-Analytical Model for Polymers) which allowed for input of the tension, compression, and shear load responses.

The matrix was tested in tension, compression, and shear and was assumed to be isotropic. Ultimate strengths of the matrix were found to be 10 580 psi in tension, 25 900 psi in compression, and 5 940 in shear. The material properties calculated suggest the resin as being an isotropic material with the moduli in tension and compression being approximately equal (3% difference between the experimental values) and the shear modulus following typical isotropic relations. Single fiber properties were obtained for the T800s fiber in tension only with the modulus being approximately 40 500 ksi and the peak stress value being approximately 309 ksi.

The material model predicts the behavior of the multi-element testing simulations in both deformation and failure in the direction of loading.