Revised damage evolution equation for high cycle fatigue life prediction of aluminum alloy LC4 under uniaxial loading

The fatigue life prediction for components is a difficult task since many factors can affect the final fatigue life. Based on the damage evolution equation of Lemaitre and Desmorat, a revised two-scale damage evolution equation for high cycle fatigue is presented according to the experimental data, in which factors such as the stress amplitude and mean stress are taken into account. Then, a method is proposed to obtain the material parameters of the revised equation from the present fatigue experimental data. Finally, with the utilization of the ANSYS parametric design language (APDL) on the ANSYS platform, the coupling effect between the fatigue damage of materials and the stress distribution in structures is taken into account, and the fatigue life of specimens is predicted. The outcome shows that the numerical prediction is in accord with the experimental results, indicating that the revised two-scale damage evolution model can be well applied for the high cycle fatigue life prediction under uniaxial loading.     

An experimental approach to low-cycle fatigue damage based on thermodynamic entropy

This paper presents an experimental approach to fatigue damage in metals based on thermodynamic theory of irreversible process. Fatigue damage is an irreversible progression of cyclic plastic strain energy that reaches its critical value at the onset of fracture. In this work, irreversible cyclic plastic energy in terms of entropy generation is utilized to experimentally determine the degradation of different specimens subjected to low cyclic bending, tension-compression, and torsional fatigue. Experimental results show that the cyclic energy dissipation in the form of thermodynamic entropy can be effectively utilized to determine the fatigue damage evolution. An experimental relation between entropy generation and damage variable is developed.     

Integrated numerical–experimental analysis of interfacial fatigue fracture in SnAgCu solder joints

In ball grid array (BGA) packages, solder balls are exposed to cyclic thermo-mechanical strains arising from the thermal mismatch between package components. Thermo-mechanical fatigue crack propagation in solder balls is almost always observed at the chip side of the bump/pad junction. The objective of the experimental part of this study is to characterize the bump/pad interface under fatigue loading. Fatigue specimens are prepared by reflowing Sn3.8Ag0.5Cu lead-free solder alloy on Ni/Au substrates. Obtained results show that fatigue damage evolution strongly depends on the microstructure. Applied strain and solder volume both have an influence on the fatigue damage mechanism. In the numerical part of the study, fatigue experiments are modeled using the finite element technique. A cohesive zone approach is used to predict the fatigue damage evolution in soldered connections. Crack propagation is simulated by an irreversible linear traction–separation cohesive zone law accompanied by a non-linear damage parameter. Cohesive zone elements are placed where failure is experimentally observed. Damage evolution parameters for normal and tangential interaction are scrutinized through dedicated fatigue tests in pure tensile and shear directions. The proposed cohesive zone model is quantitatively capable of describing fatigue failure in soldered joints, which can be further extended to a numerical life-time prediction tool in microelectronic packages.     

各向异性材料疲劳损伤模拟

根据连续损伤理论，考虑到了损伤能释放率等引起损伤的重要因素，提出了一个各向异性疲劳损伤模型。此模型结构简单，适用于各种各向异性材料。利用该模型对玻璃聚酯复合材料层板在单向受力情况下进行了寿命预测，预测值与实验值符合较好     

New approach based on continuum damage mechanics with simple parameter identification to fretting fatigue life prediction

A new continuum damage mechanics model for fretting fatigue life prediction is established. In this model, the damage evolution rate is described by two kinds of quantities. One is associated with the cyclic stress characteristics obtained by the finite element(FE) analysis, and the other is associated with the material fatigue property identified from the fatigue test data of standard specimens. The wear is modeled by the energy wear law to simulate the contact geometry evolution. A two-dimensional(2D) plane strain FE implementation of the damage mechanics model and the energy wear model is presented in the platform of ABAQUS to simulate the evolutions of the fatigue damage and the wear scar. The effect of the specimen thickness is also investigated. The predicted results of the crack initiation site and the fretting fatigue life agree well with available experimental data. Comparisons are made with the critical plane SmithWatson-Topper(SWT) method.     

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为降低用来确定疲劳极限的升降法试验的工作量，以热力学为基础，引入损伤驱动力，构建 损伤演化方程. 积分此方程得到疲劳寿命与应力或应变的理论关系. 对光滑试件，根据成组 法疲劳试验结果利用最小二乘法拟合包括疲劳极限在内的材质参数. 利用损伤力学方法求得 高应力区的疲劳寿命曲线，由此递推得到低应力区寿命值和疲劳极限. 所得理论疲劳极限值 与升降法疲劳试验结果十分吻合. 节约了疲劳试验的机时、费用与人力.     

考虑孔洞影响的铸造镁合金ZM6疲劳寿命预估方法

铸造镁合金ZM6是一种应用于直升机减速器机匣制造的典型材料。然而,在铸造过程中产生的内部缺陷对材料的疲劳性能有显著影响。本文研究了含内部孔洞缺陷ZM6材料的疲劳损伤模型和寿命预估方法。首先,采用X射线断层扫描技术,对三个批次毛坯料制成的试验件进行扫描观察,获得了试验件内部孔洞的分布特征。进而,对48件试验件进行了两种应力比下多级应力水平的疲劳试验,获得了各批次试验件寿命结果,并通过观察与分析,得出了孔隙率和近表面较大孔洞为影响试验件疲劳寿命的两个关键因素。然后,基于损伤力学理论提出了通过材料初始弹性模量和等效孔洞局部应力应变场来分别反映孔隙率和近表面较大孔洞影响的疲劳损伤模型和寿命计算方法,并结合ABAQUS软件平台实现了含孔洞试验件的疲劳损伤计算和寿命计算。最后,采用所提理论模型和计算方法给出了试验件的疲劳寿命预测结果,并与试验结果进行了不同维度的对比,验证了所提模型与方法的有效性和适用性。     

半结晶聚合物损伤演化的实验表征与数值模拟

损伤本构模型对研究材料的断裂失效行为有重要意义, 但聚合物材料损伤演化的定量表征实验研究相对匮乏. 通过4种高密度聚乙烯(high density polythylene, HDPE)缺口圆棒试样的单轴拉伸实验获得了各类试样的载荷-位移曲线和真应力-应变曲线, 采用实验和有限元模拟相结合的方法确定了HDPE材料不同应力状态下的本构关系, 并建立了缺口半径与应力三轴度之间的关系;采用两阶段实验法定量描述了4种HDPE试样单轴拉伸过程中的弹性模量变化, 并建立了基于弹性模量衰减的损伤演化方程, 结合中断实验和扫描电子显微镜分析了应力状态对HDPE材料微观结构演化的影响. 结果表明缺口半径越小, 应力三轴度越大, 损伤起始越早、演化越快; 微观表现为: 高应力三轴度促进孔洞的萌生和发展, 但抑制纤维状结构的产生;基于实验和有限元模拟获得的断裂应变、应力三轴度、损伤演化方程等信息提出了一种适用于聚合物的损伤模型参数确定方法, 最后将本文获得的本构关系和损伤模型用于HDPE平板的冲压成形模拟, 模拟结果与实验结果吻合良好.      

Strength of damaged polycarbonate after fatigue

A fatigue damage model is proposed to establish a predictive formula for the fatigue service life of polycarbonate (PC) materials. A damage variable is introduced in terms of remaining fracture strain, and a new fatigue damage evolution relation is derived to characterize the extent of fatigue damage after a certain number of loading cycles. Fatigue tests were conducted to construct the stress amplitude versus the fatigue life curve. After different numbers of cycles of fatigue, the new damage variable for PC materials was measured by pulling damaged specimens to fracture under monotonic loading. Experimental results on damage evolution and fatigue life have a good agreement with those predicted by the proposed damage model.     

AN ENERGY APPROACH TO RAPIDLY ESTIMATE FATIGUE BEHAVIOR BASED ON INTRINSIC DISSIPATION

材料疲劳损伤的累积过程是一个伴随着温度变化的能量耗散过程. 相比于疲劳过程中试件的局部温升,固有耗散是材料能量变化的直接反映,与材料微观结构演化联系也更为紧密,因此以材料的固有耗散作为疲劳损伤指标具有更加明确的物理意义. 基于对试件表面温升的一维双指数回归,构建了一种材料固有耗散的计算模型,并在此基础上提出了一种快速评估材料疲劳性能的能量方法. 利用该能量方法,对FV520B 钢的疲劳性能进行了实验研究,并对实验结果进行了分析与对比,从而证明了该能量方法及计算模型的可行性和有效性.     

两级载荷下复合材料层板疲劳与寿命预测

研究了复合材料层板疲劳过程中的累积应变演化规律，建立了以累积应变为基础的非线性积累损伤法则，实验结果表明：文中提出的累积应变方法能够较好地反映加载次序效应，准确地预测了复合材料层板在两级载荷下的疲劳寿命。     

基于固有耗散的材料疲劳性能快速评估方法

材料疲劳损伤的累积过程是一个伴随着温度变化的能量耗散过程. 相比于疲劳过程中试件的局部温升,固有耗散是材料能量变化的直接反映,与材料微观结构演化联系也更为紧密,因此以材料的固有耗散作为疲劳损伤指标具有更加明确的物理意义. 基于对试件表面温升的一维双指数回归,构建了一种材料固有耗散的计算模型,并在此基础上提出了一种快速评估材料疲劳性能的能量方法. 利用该能量方法,对FV520B 钢的疲劳性能进行了实验研究,并对实验结果进行了分析与对比,从而证明了该能量方法及计算模型的可行性和有效性.      

基于韧性耗散模型的损伤定量分析方法

材料的静力韧性便于工程测量,对疲劳损伤较其它宏观损伤变量更敏感。本文以材料静力韧性为宏观损伤变量,依据疲劳过程中金属材料韧性随疲劳循环加载而变化的实验结果的规律分析,得到了应力和循环数表达的损伤演化方程和损伤累积模型。该模型能较好地反映加载顺序的影响。推导出该疲劳损伤累积模型在多级加载下的递推公式。经四种金属材料疲劳试验数据验证结果表明,该模型预测疲劳寿命是较为满意的。由于疲劳试验数据分散性大,结果有待进一步验证。     

基于微-细观机理的混凝土疲劳损伤本构模型

该文致力于混凝土疲劳损伤发展机理的微细观解释. 以速率过程理论为基础,通过考虑裂纹断裂过程区中的水分子动力作用,在细观尺度上建立了具有物理机理的疲劳损伤能量耗散表达式. 结合细观随机断裂模型,以宏观损伤力学为框架,建立了疲劳损伤演化方程. 通过数值模拟,计算了单轴受拉时的疲劳损伤演化以及不同加载幅度下的疲劳寿命. 与相关试验结果的对比显示出该文模型能够很好地表现混凝土材料的疲劳损伤演化过程.      

THE FATIGUE CONSTITUTIVE MODEL OF CONCRETE BASED ON MICRO-MESO MECHANICS

该文致力于混凝土疲劳损伤发展机理的微细观解释. 以速率过程理论为基础,通过考虑裂纹断裂过程区中的水分子动力作用,在细观尺度上建立了具有物理机理的疲劳损伤能量耗散表达式. 结合细观随机断裂模型,以宏观损伤力学为框架,建立了疲劳损伤演化方程. 通过数值模拟,计算了单轴受拉时的疲劳损伤演化以及不同加载幅度下的疲劳寿命. 与相关试验结果的对比显示出该文模型能够很好地表现混凝土材料的疲劳损伤演化过程.     

Experimental determination of damage parameters in uniaxially-loaded metal-matrix composites using the overall approach

A recently developed damage-plasticity model for metal matrix composites is examined using the overall approach to damage. In this approach, the damage mechanisms in the composite system are reflected through a single overall damage tensor assuming an elasto-plastic matrix with elastic fibers. It is shown how the model is applied to uniaxially loaded metal-matrix specimens. Each specimen is a symmetric laminate composed of four plies with different orientations. A numerical procedure is formulated and implemented to calculate the stresses, strains, and damage variables in these specimens.

In order to test the validity of the model, a series of uniaxial test experiments are conducted for the damage characterization of the metal-matrix composite. The experiments are conducted on a titanium aluminide SiC-reinforced laminate. Laminate layups of (0/90)s and (± 45)s are tested under uniaxial tension. In order to investigate and model damage evolution, each specimen is loaded to different load levels ranging from the fracture load to 70% of fracture load. Scanning electron microscopy is performed on representative cross-sections of all specimens. This information is then used to quantify damage in the composite system. Damage variables are defined based on the crack density and correlated with the theoretical model. The experimental and numerical results are then compared. Certain recommendations are finally made concerning the determination of damage parameters in metal-matrix composites.     

Fatigue and damage tolerance behaviour of corroded 2024 T351 aircraft aluminum alloy

The fatigue and damage tolerance behaviour of pre-corroded 2024 T351 aluminum alloy specimens has been investigated and compared to the behaviour of the uncorroded material. The experimental investigation was performed on specimens pre-corroded in exfoliation corrosion environment and included the derivation of S–N and fatigue crack growth curves as well as measurements of fracture toughness. The fatigue crack growth tests were performed for different stress ratios R. To obtain reference material behaviour all mechanical tests were repeated under the same conditions for uncorroded specimens. For the corroded material an appreciable decrease in fatigue resistance and damage tolerance was obtained. The results of the experimental investigation were discussed under the viewpoint of corrosion and corrosion-induced hydrogen embrittlement of the 2024 aluminum alloy. The need to account for the influence of pre-existing corrosion on the material’s properties in fatigue and damage tolerance analyses of components involving corroded areas was demonstrated.     

FATIGUE PROPERTY BASED ON NOTCHED SPECIMEN TESTS

缺口件疲劳问题的研究日益引起各国学者的重视. 局部应力-应变法以其简单性在工程中得到了广泛应用, 该方法通常会得到偏于安全的结果. 引入疲劳缺口因子代替弹性应力集中因子针对缺口疲劳进行研究, 仍未能从本质上改善预测结果的准确性. 考虑到"热点应力" 附近的相对应力梯度, 提出了应力梯度法研究缺口件疲劳问题, 这一概念亦被用于应力场强度方法中, 如何准确确定损伤区域是应力场强度方法需要解决的问题. 临界距离理论可将Neuber 律、Peterson 方法及应力场强度方法进行有效统一, 同时有限元方法的发展进一步支持了该理论. 目前, 该方法在高周疲劳研究中取得了较好的效果, 但对低周疲劳寿命预测的有效性仍需进一步的验证.     

Fatigue growth prediction of elliptical cracks in welded joint structure: Hybrid and energy density approach

A hybrid weight function approach (HWFM) is presented for the fatigue life prediction of infinite body and welded joint structure containing elliptical cracks. A self-containing computer code has been developed for this purpose. Numerical computations were first conducted on cracked infinite body showing a physical fact, that the elliptical shape of the crack becomes circular during its evolution. The prediction of the fatigue crack growth shows that the present results are in perfect concordance with those reported in the literature. Then, numerical tests were carried out on two types of specimens of welded joint structure. The present results were compared to the experimental and predicted ones of other authors, demonstrating that the hybridization method is a powerful numerical technique, and that the SEDF approach (using the Sih’s law) is more valid for the critical cases of welded joints than the SIF approach (using the Paris law). A parametric study has been conducted on the stress ratio “R” showing that the fatigue life to failure decreases with the increase of “R”.     

柔性路面的各向异性疲劳损伤数值模型研究

根据柔性路面在交通荷载作用下的力学响应特点,推导了一个各向异性疲劳损伤本构方程,并基于ABAQUS软件及其二次开发平台,建立了考虑各向异性疲劳损伤的路面结构有限元模型。通过建立的模型计算车辆作用下路面结构的疲劳寿命,其结果与试验数据吻合良好,误差最高仅为3.8%,证明该模型精确可靠。最后,分析了疲劳损伤的演化规律,以及路面结构参数对疲劳性能的影响。结果表明,路面纵向疲劳损伤演化速率比横向大得多,随着车辆循环作用,路面结构的各向异性逐渐增强,进而又加剧疲劳损伤的演化。另外,沥青层越厚、土基弹性模量越大,路面疲劳损伤演化得越慢;而当土基较弱、沥青层较薄时,增加级配碎石层厚度可以显著延缓柔性路面的疲劳开裂。