Effect of welding process on fatigue crack growth behaviour of austenitic stainless steel welds in a low alloy (Q & T) steel

Fatigue crack growth behaviour from a lack of penetration (LOP) defect in austenitic stainless steel weld metals of cruciform joints made of a low alloy high strength (Q & T) steel has been studied to understand the effect of two welding processes, namely, shielded metal arc welding (SMAW) and flux cored arc welding (FCAW). Fatigue crack growth studies were carried out at a stress ratio of R = 0 and a frequency of 90 to 110 Hz in a resonant testing equipment (Rumul, Model:8601). Crack growth rates were relatively lower in the weld metal obtained by flux cored arc welding process. Microstructural features observed revealed marked difference in the morphology of delta ferrite for the welded joints obtained from the above two welding processes. Long streaks of delta ferrite in austenite matrix were found in case of SMAW-weld metal which seem to have lowered the resistance to the fatigue crack propagation. A discontinuous network of delta ferrite found in austenite matrix in the case of FCAW-weld metal seems to have contributed to slower propagation of fatigue crack. Fractographic features also substantiate the observed trends in the fatigue crack growth behaviour.     

Comprehensive numerical analysis of a three-pass bead-in-slot weld and its critical validation using neutron and synchrotron diffraction residual stress measurements

The current paper presents a finite element simulation of the residual stress field associated with a three pass slot weld in an AISI 316LN austenitic stainless steel plate. The simulation is split into uncoupled thermal and mechanical analyses which enable a computationally less expensive solution. A dedicated welding heat source modelling tool is employed to calibrate the ellipsoidal Gaussian volumetric heat source by making use of extensive thermocouple measurements and metallographic analyses made during and after welding. The mechanical analysis employs the Lemaitre–Chaboche mixed hardening model. This captures the cyclic mechanical response which a material undergoes during the thermo-mechanical cycles imposed by the welding process. A close examination of the material behaviour at various locations in the sample during the welding process, clearly demonstrates the importance of defining the correct hardening and high temperature softening behaviour. The simulation is validated by two independent diffraction techniques. The well-established neutron diffraction technique and a very novel spiral slit X-ray synchrotron technique were used to measure the residual stress–strain field associated with the three-pass weld. The comparison between the model and the experiment reveals close agreement with no adjustable parameters and clearly validates the used modelling procedure.     

Fatigue life prediction of welded cruciform joints using strain energy density factor approach

The influences of two welding processes, namely, shielded metal arc welding (SMAW) and flux cored arc welding (FCAW), on fatigue life of cruciform joints containing lack of penetration (LOP) defects have been analyzed by using the strain energy density factor (SEDF) approach. Load carrying cruciform joints were fabricated from ASTM 517 ‘F’ grade steel. Fatigue crack growth experiments were carried out in a mechanical resonance vertical pulsator (SCHENCK 200 kN capacity) with a frequency of 30 Hz under constant amplitude loading (R=0). It was found that the fatigue lives of the cruciform joints fabricated by SMAW process were relatively higher than the FCAW counterpart. Moreover, fracture mechanics equations have been developed to predict the fatigue life of the cruciform joints fabricated by the above-mentioned two processes.     

Effect of weld size on fatigue crack growth behaviour of cruciform joints by strain energy density factor approach

The effect of weld size on fatigue crack growth behaviour of cruciform joints containing lack of penetration defect has been analysed by using the strain energy density factor concept. Load carrying cruciform joints were fabricated from ASTM 517‘F' grade steel. Fatigue crack growth experiments were carried out in a mechanical resonance vertical pulsator (SCHENCK 200 kN capacity) with a frequency of 30 Hz under constant amplitude loading (R=0). It was found that the crack growth rates were relatively lower in the larger welds fabricated by multipass welding technique than the smaller welds fabricated by the single pass welding technique.     

Very high cycle fatigue behavior of bridge steel welded joint

Very high cycle fatigue (VHCF) behaviors of bridge steel (Q345) welded joints were investigated using an ultrasonic fatigue test system at room temperature with a stress ratio R = ?1. The results show that the fatigue strength of welded joints is dropped by an average of 60% comparing to the base metal and the fatigue failure still occurred beyond 10⁷ cycles. The fatigue fracture of welded joints in the low cycle regime generally occurred at the solder while at the heat-affected zone (HAZ) in the very high cycle regime. The fatigue fracture surface was analyzed with scanning electron microscopy (SEM), showing welding defects such as pore, micro-crack and inclusion were the main factors on decreasing the fatigue properties of welded joints. The effect of welding defects on the fatigue behaviors of welded joints was discussed in terms of experimental results and finite element simulations.     

氩弧点焊薄片应变传感器性能实验研究

对氩弧点焊薄片应变传感器传递性能和疲劳性能进行了试验研究,试验结果表明氩 弧点焊薄片应变传感器具有稳定传递性能和可靠的疲劳性能,可以应用于实际工程应变测 量.     

用升降法求95连杆疲劳极限的探讨

为了较精确地求出95连杆的疲劳极限,本文将在材料疲劳试验中应用较广的升降法推广应用于连杆,给出了用升降法求构件疲劳极限的基本过程。文中首先选取了试验的控制因素并确定了连杆的控制点(应力被选定为控制应力的点定义为控制点)。然后在四级应力水平下进行了连杆的疲劳试验,并以最大应力幅点的应力为计算应力求出了连杆的疲劳极限。     

Increasing the Fatigue Life of Dissimilar Friction Stir Spot Welded Al/Cu Joints by Optimization of Technological Parameters

Friction stir spot welding is a new technique used in industries for spot joining dissimilar combinations. In this investigation, dissimilar combinations of Al5052 aluminium and C10100 copper are joined by using this technique with variations of important process parameters, such as the tool rotational speed, dwell duration, and plunging depth. A central composite design model is developed for establishing empirical relationships between the process parameters and the fatigue life of the joints (number of cycles to fracture). The analysis of variance is used for determining the significance of the developed model. The response surface methodology is used for maximizing the fatigue strength. By confirmation experiments, the model is validated, and the error is found to be within four percent.     

金属管线高温环境下的断裂失效分析

超燃冲压发动机燃烧室试验台配置了大量金属管线,煤油作为燃料和冷却介质在其中输运,在实验过程中发生管线早期断裂失效,对此开展了分析。首先利用三维体视显微镜与扫描电镜进行了断口观察与分析,表明管线的开裂起源于焊缝根部,具有典型的多源起源特征;裂纹源区具有蓝色半圆形特征,表明存在焊接裂纹。同时,断口呈现明显的疲劳辉纹,间距为亚微米量级。根据辉纹间距与管材壁厚以及使用寿命分析,确定了疲劳载荷的频率范围;根据理论公式与有限元模态分析对管线的自振频率进行了估算,其结果与断口分析的结果吻合良好。以上研究结果表明管线断裂是典型的振动疲劳失效导致的。为此,建议在管线中部增加固定点约束,改变管线的自振频率以降低振幅,并改进焊接工艺,提高管线焊接质量。基于以上措施,有效解决了管线的早期断裂失效问题。     

未熔透尺寸对十字焊接接头疲劳性能影响规律试验研究

针对某厂一压力机架的焊接结构，采用极大似然方法，进行了部分熔透焊接十字接头的拉—拉疲劳试验，得到了该类结构的Ｐ－Ｓ－Ｎ对数曲线。研究了未熔透尺寸对接头的应力集中系数、疲劳强度和试件疲劳破坏形式的影响规律，结果表明，在焊缝与母材等强的情况下，当未熔透尺寸２ａ／Ｔ＜０．５时，其疲劳性能无明显减弱；而当未熔透尺寸２ａ／Ｔ＞０．５时，则接头的抗疲劳性能有显著的改变。     

Analysis of short crack growth from microscopic fatigue properties

Successful simulation of kinetics of small fatigue crack growth entails three aspects: Stage I, Stage II growth rate prediction and transition prediction. In this paper attention is focused on growth rate predictions. By using microstructurally-affected-zone and process zone concepts, microscopic fatigue behaviour of small fatigue crack propagation is logically linked with macroscopic fatigue behaviour, showing an intrinsic relation between small fatigue crack growth and macroscopic low-cycle fatigue properties during crack growth. Furthermore, variation of relatively big plastic zone size associated with a growing small fatigue crack is kinetically simulated. As a result a quantitative prediction model of growth rates for Stage I and Stage II growth has been developed whose explicit advantage is that the growth rate of small fatigue crack can now be predicted in terms of bulk fatigue properties in conjunction with local microstructural characteristics.     

Approaches in computational welding mechanics applied to additive manufacturing: Review and outlook

The development of computational welding mechanics (CWM) began more than four decades ago. The approach focuses on the region outside the molten pool and is used to simulate the thermo-metallurgical-mechanical behaviour of welded components. It was applied to additive manufacturing (AM) processes when they were known as weld repair and metal deposition. The interest in the CWM approach applied to AM has increased considerably, and there are new challenges in this context regarding welding. The current state and need for developments from the perspective of the authors are summarised in this study.     

基于LHS-Kriging法的正交异性钢桥面板疲劳可靠度分析

为解决随机车载下正交异性钢桥面板疲劳应力谱有限元求解耗时问题,采用拉丁超立方抽样（LHS）与Kriging方法,建立了快速获取随机车流作用下细节疲劳应力谱的LHS-Kriging有限元替代模型,并将此模型应用于南溪长江大桥正交异性钢桥面板疲劳可靠度计算。结果表明,基于LHS-Kriging方法的有限元替代模型, 不需要经过大量车辆荷载的有限元加载,可直接快速获取细节疲劳应力谱;与传统的响应面法（RSM）相比,Kriging法预测的细节等效疲劳应力更符合有限元计算结果;随着交通量增长率的增大,桥梁的疲劳可靠度显著减少;100年后,当交通量增长率为3%和5%时,正交异性桥面板与纵肋焊接处的细节疲劳可靠度小于2。     

Frequency-dependent random fatigue of panel-type structures made of ceramic matrix composites

The panel-type structures used in aerospace engineering can be subjected to severe highfrequency acoustic loadings in service. This paper evaluates the frequency-dependent random fatigue of panel-type structures made of ceramic matrix composites(CMCs) under acoustic loadings. Firstly, the high-frequency random responses from the broadband random excitation will result in more stress cycles in a deinite period of time. The probability density distributions of stress amplitudes will be different in different frequency bandwidths, though the peak stress estimations are identical. Secondly, the fatigue properties of CMCs can be highly frequency-dependent. The fatigue evaluation method for the random vibration case is adopted to evaluate the fatigue damage of a representative stiffened panel structure. The frequency effect through S-N curves on random fatigue damage is numerically veriied. Finally, a parameter is demonstrated to characterize the mean vibration frequency of a random process, and hence this parameter can further be considered as a reasonable loading frequency in the fatigue tests of CMCs to obtain more reliable S-N curves.Therefore, the inluence of vibration frequency can be incorporated in the random fatigue model from the two perspectives.     

欧洲近海结构用钢研究计划的进展

欧洲近海结构用钢研究计划在第一阶段(1975—80年)关于海洋焊接结构在疲劳载荷下工作性能的研究基础上,于1981—87年继续进行了第二阶段的研究工作。参加国家有欧洲经济共同体6国及挪威、加拿大等。本文综合报道第二阶段研究情况与主要成果,内容包括:板厚对疲劳强度的影响,焊后改进技术与腐蚀疲劳,疲劳载荷及变幅疲劳试验,疲劳分析的断裂力学方法,某些管节点的应力分析等;并对研究计划的背景及今后研究工作的方向作了介绍。      

单向加载,平均应力下的疲劳短裂纹生长

本文报道单向加载下平均应力和交变应力对疲劳短裂纹生长的影响。采用一种1.99%NiCrMo钢,在平均应力和交变应力不同组合的应力控制条件下进行室温疲劳试验,将疲劳过程划分为3个阶段:塑性局部化,微观组织短裂纹(MSC)生长和物理短裂纹(PSC)生长,研究了平均应力对上述3个阶段的影响并得到一组关系式,这些关系式可预测多种平均应力和交变应力组合条件下短裂纹的初始阶段和生长行为。获得了不同平均应力下疲劳承载曲线的满意的预测结果。本研究为仍依赖于传统的Goodman疲劳图的设计人员提供了一种以疲劳过程物理机制为基础的方法。     

纤维增强复合材料的破坏机理

纤维增强复合材料本身是一个非均匀各向异性力学结构。复合材料的研制、设计和使用都与力学密切相关。复合材料的破坏机理比金属材料复杂,不同组分的构成使其在加工中存在和使用中带来的缺陷比金属多。它的破坏机理与纤维、基体组分的性能,粘结强度,纤维铺设方向和顺序,工作条件等有关。需要采用有效的试验和分析方法,研究复合材料在不同      

一种统一的多轴疲劳损伤参量

城分析多轴损伤临界面上的应变化特性的基础上,根据多轴疲劳临界损伤平面原理,提出利用多轴介面上的最大剪切应变幅与相临两个最大剪切应变值之间的法向应变幅所合成的ｖｏｎ Ｍｉｓｅｓ等效应变幅作为多轴疲劳损伤参量,该参量不含有任何材料常数,不仅能够适用于多轴比例与非比例加载下,而且可退化成单轴的形式,经四种材料的试验验证,结果是令人满意的。     

纤维增强树脂基复合材料多轴疲劳研究进展

纤维增强树脂基复合材料结构在工程应用中常常承受复杂载荷的作用, 从而使材料处于多轴循环应力条件下. 为了更加合理地进行复合材料结构设计, 必须对复合材料多轴疲劳行为进行深入的研究, 建立比较理想的复合材料疲劳寿命预测模型. 首先简单回顾了复合材料单轴疲劳损伤判据及其寿命预测模型, 然后结合作者的研究结果, 总结了近年来国内外纤维增强树脂基复合材料多轴疲劳理论的研究成果, 对各种失效准则、疲劳寿命预测模型进行了较为深入的分析, 指出了它们各自的特点及其存在的问题, 并对复合材料多轴疲劳理论的研究趋势作出了展望. 最后, 对目前常用的复合材料多轴疲劳实验方法进行了总结, 并指出了各种方法的优缺点及其实验中存在的困难.