Mechanical Properties of Hard W-C Coating on Steel Substrate Deduced from Nanoindentation and Finite Element Modeling

Mechanical properties of a hard and stiff W-C coating on steel substrate have been investigated using nanoindentation combined with finite element modeling (FEM) and extended FEM (XFEM). The significant pile-up observed around the indents in steel substrate caused an overestimation of hardness and indentation modulus. A simple geometrical model, considering the additional contact surfaces due to pile-up, has been proposed to reduce this overestimation. The presence of W-C coating suppressed the pile-up in the steel substrate and a transition to sink-in behavior occurred. The FEM simulations adequately reproduced the surface topography of the indents in the substrate and coating/substrate systems as well. The maximum principal stresses of the indented W-C/steel coated system were tensile; they were always located in the coating and evolved in 3 stages. Cohesive cracking occurred during loading in the sink-in zone (stage III) when the ultimate tensile strength (σ _max ) of the coating was reached. The obtained hardness (H _c ), indentation modulus (E _c ), yield stress (Y) and strength (σ _max ) of the W-C coating were H _c ? =?20 GPa, E _c ? =?250 GPa, Y?=?9.0 GPa and σ _max ? =?9.35 GPa, respectively. XFEM resulted in fracture energy of the W-C coating of G?=?38.1 J?·?m^-2 and fracture toughness of K _IC ? =?3.5 MPa?·?m^0.5.     

Pressure-sensitive ductile layers – I. Modeling the growth of extensive damage

Polymeric adhesives sandwiched between two elastic substrates are commonly found in multi-layers and IC packages. The non-elastic deformation and flow stress of such adhesive joints are highly pressure-sensitive. In this work, we study the effects of pressure-sensitivity, α, and plastic dilatancy, β, on void growth and coalescence ahead of a crack in ductile adhesive joints. To this end, a single layer of discrete voids is placed ahead of the crack in a pressure-sensitive dilatant adhesive sandwiched between two elastic substrates. The adhesive joint is subjected to small-scale yielding conditions. Using an associated flow rule (α = β), we show that pressure-sensitivity not only intensifies damage levels but also increases its spatial extent several fold. The damage level as well as its spatial extent is found to be even greater when a non-associated flow rule (β < α) is deployed. A reduction in the damage process zone’s thickness further increases the voiding activity in the adhesive, thereby resulting in brittle-like failure. This work also examines the fracture toughness trends using a material failure criterion for crack growth.     

Cohesive zone finite element analysis of crack initiation from a butt joint’s interface corner

Cohesive zone (CZ) fracture analysis techniques are used to predict the initiation of crack growth from the interface corner of an adhesively bonded butt joint. In this plane strain analysis, a thin linear elastic adhesive layer is sandwiched between rigid adherends. There is no preexisting crack in the problem analyzed, and the focus is on how the shape of the traction–separation (T–U) relationship affects the predicted joint strength. Unlike the case of a preexisting interfacial crack, the calculated results clearly indicate that the predicted joint strength depends on the shape of the T–U relationship. Most of the calculations used a rectangular T–U relationship whose shape (aspect ratio) is defined by two parameters: the interfacial strength σ¹ and the work of separation/unit area Γ. The principal finding of this study is that for a specified adhesive layer thickness, there is any number of σ¹, Γ combinations that generate the same predicted joint strength. Each combination corresponds to a different CZ length. An approximate CZ-like elasticity solution was developed to show how such combinations arise and their connection with the CZ length.     

Revisiting the perforation of ductile plates by sharp-nosed rigid projectiles

The process of ductile plate perforation by sharp-nosed rigid projectiles is further examined in this work through 2D numerical simulations. We highlight various features concerning the effective resisting stress (σ_r) which a finite thickness plate, with a flow stress of Y_t, exerts on the projectile during perforation. In particular, we show that the normalized resisting stress (σ_r/Y_t) can be represented as a unique function of the normalized thickness of the plate (H/D, where H is plate thickness and D is projectile diameter), for a large range of normalized thicknesses. Our simulations for very thin target plates show that the penetration process is achieved through the well-known dishing mechanism, where the target material is pushed forward by the projectile’s nose. An important observation, which emerges from our simulations, is that the transition between the dishing and the hole enlargement mechanisms takes place at a normalized thickness of about H/D = 1/3. We also find that the normalized resistive stress for intermediate plate thicknesses, 1/3 < H/D < 1.0, is relatively constant at a value of σ_r/Y_t = 2.0. This range of thicknesses conforms to a state of quasi plane stress in the plates. For thicker plates (H/D > 1) the σ_r/Y_t ratio increases monotonically to values which represent the resistance to penetration of semi-infinite targets, where the stress state is characterized by plane strain conditions. Using a simple model, which is based on energy conservation, we can predict the values of the ballistic limit velocities for many projectile/target combinations, provided the perforation is done through the ductile hole enlargement mechanism. Good agreement is demonstrated between predictions from our model and experimental data from different sources, strongly enhancing the confidence in both the validity and usefulness of our model.     

A stress analytical solution for Mode III crack within modified gradient elasticity

The strain gradient exists near a crack tip may significantly influence the near-tip stress field. In this paper, the strain gradient and the internal length scales are introduced into the basic equations of mode III crack by the modified gradient elasticity (MGE). By using a complex function approach, the analytical solution of stress fields for mode III crack problem is derived within MGE. When the internal length scales vanish, the stress fields can be simplified to the stress fields of classical linear elastic fracture mechanics. The results show that the singularity of the shear stress is made up of two parts, r^−1/2 part and r^−3/2 part, and the sign of the stress σ_yz changes. With the increase of l_x, the peak value of σ_yz decrease and its location moves farther from the fracture vertex. The influence of strain gradient for mode III crack problem cannot be ignored.     

An experimental investigation of crack-path directional stability

Using the criterion that a crack will extend perpendicular to the maximum circumferential stress,σ _θ, we show that the directional stability of crack growth is governed by the location of microcrack initiation ahead of the crack tip. At distances greater than a geometrical radiusr _o, the maximum value ofσ _θ deviates from the position of symmetry. Thus, if we assume that the physical processes involved in fracture lead to crack initiation at a distancer _c ahead of the crack tip, the criterion for directional stability isr _o>r _c. Experimental and theoretical values ofr _o verify that, asr _o becomes small, the crack's directional stability deteriorates. Observing that a lengthwise compressive stress increasesr _o, a center-cracked specimen was developed which allows the application of controlled lengthwise compression independently of the opening-mode load. A detailed photoelastic analysis of the specimen has provided the value ofr _o as a function of the crack length. The value ofr _o is then compared with the expected microcrack initiation distances in ductile fracture. By applying sufficient lengthwise compression, we are able to make the crack grow straight and obtain numerous data points from this specimen which would otherwise be directionally unstable. The results indicate that, as the total lengthwise tensile stress at the crack tip increases, the fracture toughness also increases. Using this information we can then adjustK _Ic for zero lengthwise loading and obtain a geometry independent fracture toughness.     

The boundary layers of an unsteady incompressible stagnation-point flow with mass transfer

In the current work, the boundary layers of an unsteady incompressible stagnation-point flow with mass transfer were further investigated. Similarity transformation technique was used and the similarity equation group was solved using numerical methods. Interesting observation is that there are multiple solutions seen for negative unsteadiness parameters, β. The influences of mass transfer, unsteadiness parameter, and Prandtl numbers on velocity and temperature profiles, wall drag, and wall heat fluxes were investigated and analyzed. The asymptotic behaviors for the similarity equations in limiting situations were theoretically analyzed. It is found that solutions exist for all mass transfer parameters for β≥−1. For a certain mass transfer parameter, there are two solutions when β_c<β<0; there is one solution for (β=β_c)∪(β≥0); there is no solution for β<β_c, where β_c is a critical unsteadiness parameter dependent on mass transfer parameter.     

Homogenization of a degenerate parabolic problem in a highly heteregeneous mediumHomogénéisation d'un problème parabolique dégénéré dans un milieu fortement hétérogène

We consider the homogenization of a time-dependent heat transfer problem in a highly heteregeneous periodic medium made of two connected components having finite heat capacities c_α(x) and heat conductivities a_α(x), α=1,2, of order one, separated by a third material with thickness of order ε the size of the basic periodicity cell, but with conductivity λa₃(x) where a₃=O(1) and λ tends to zero with ε. Assuming only that c_i(x)?0 a.e., such that the problem can degenerate (parabolic-elliptic), we identify the homogenized problem following the values of δ=lim_ε→0ε²/λ. To cite this article: M. Mabrouk, A. Boughammoura, C. R. Mecanique 331 (2003).     

A transition phenomenon of ice formation in water flow between two horizontal parallel plates

Experiments have been performed to investigate the icetransition profiles and heat-transfer characteristics for water flows between two horizontal parallel plates. The experiments are carried out under the condition that upper plate is cooled at uniform temperature kept less than freezing temperature of water, while the lower plate is heated at uniform temperature kept higher than the temperature of water flow. The temperatures of the upper and lower plates range from ?8 to ?14°C and from 10 to 60 °C, respectively, with inlet-water temperature varied from 1.5 to 4.5 °C. The cooling and heating temperature ratios, θ_c and θ_h, are ranging from 1.78 to 9.33 and from 1.22 to 39, respectively. By using three kinds of heightH of 16, 30 and 40 mm between the horizontal parallel plates, the Reynolds and Grashof numbers are varied from 3.2 × 10² to 1.5 × 10⁴ and from 3.4 × 10³ to 8.97 × 10⁶, respectively. As a result of this investigation two ice-transition modes are observed. The first ice-transition mode is due to an interruption of upper and lower thermal boundary layers, while the second mode is due to an instability of laminar boundary layer formed on water-ice interface. In order to determine the kind of ice-transition mode, criterion correlation formulas including the Reynolds numberRe _H , Grashof numberGr _H , and heating temperature ratio θ_h are determined and may be written as follows: For thermal icetransition mode (th.I.T.M.)Re _H /(Gr _H ·θ _h )^0.23<1.6×10^?3 and for hydrodynamical ice-transition mode (hy.I.T.M.)Re _H /(Gr _H ·θ _h )^0.23>2.3×10^?3 By introducing the freezing parameterB _f , correlation equations for local and mean Nusselt numbers along the water-ice interface at steady-state condition are determined. From the current experimental results it is found that the local Nusselt number may be described as the following equation:Nu _x =0.835 Re _H ^0.278 · B _f ^0.834 ·x/H)^?0.139     

Stress singularity analysis around the singular point on the stress singularity line in three-dimensional joints

The characteristics of the stress fields around a singular point on the stress singularity line of dissimilar materials in three-dimensional joints are investigated using BEM. Contour for the order of stress singularity around the point is mapped on Dundurs’ parameters plane using eigen value analysis by FEM. The results in 3D joints are compared with those in 2D joints having the same cross section and material combination. The order of stress singularity around the singular point on the stress singularity line in 3D joints is almost identical with that in 2D joints in the singularity region. However, the zero boundary of singularity in 3D joints is slightly different from that in 2D joints. Furthermore, the multiple root of p = 1 exists in the eigen value analysis by FEM. Therefore, logarithmic singularity possibly occurs around the singular point on the stress singularity line. Then, the stress distributions around this point are expressed by the combination of the r^λ term and logarithmic singularity terms. Finally, the characteristics of the stress intensity factors of the r^λ term and logarithmic singularity terms around the singular points are investigated.     

Tensile-shear transition in mixed mode I/III fracture

The propensity of the transition of fracture type in either brittle or ductile cracked solid under mixed-mode I and III loading conditions is investigated. A fracture criterion based on the competition of the maximum normal stress and maximum shear stress is utilized. The prediction of the fracture type is determined by comparing τ_max/σ_max at a critical distance from the crack tip to the material strength ratio τ_C/σ_C, i.e., (τ_max/σ_max)<(τ_C/σ_C) for tensile fracture and (τ_max/σ_max)>(τ_C/σ_C) for shear fracture, where σ_C (τ_C) is the fracture strength of materials in tension (shear). Mixed mode I/III fracture tests were performed using circumferentially notched cylindrical bars made of PMMA and 7050 aluminum alloy. Fracture surface morphology of the specimens reveals that: (1) for the brittle material, PMMA, only tensile type of fracture occurs, and (2) for the ductile material, 7050 aluminum alloy, either tensile or shear type of fracture occurs depending on the mode mixity. The transition (in ductile material) or non-transition (in brittle material) of the fracture type and the fracture path observed in experiments were properly predicted by the theory. Additional test data from open literature are also included to validate the proposed theory.     

The coefficient of normal restitution for the Hertzian contact of two rough spheres colliding in a viscous fluid

We use previous theoretical results for the added mass, history and lubrication forces between two spheres colliding in a fluid with viscosity ν to investigate the effect of viscous dissipation on the coefficient of restitution during contact. We assume that the mechanical interaction is governed by Hertzian mechanical contact of small duration τ and that the minimum approach distance between particles is approximately equal to the height σ of surface micro-asperities. A non-dimensionalization of the equation of motion indicates that the contact dynamics is governed by two parameters – the ratio ϵ of the surface roughness σ and the sphere radius a, and a contact Stokes number defined as St_c = σ²/ντ. An asymptotic solution of the equation of motion in the limit of small ϵ/St_c is used to obtain an explicit expression for the coefficient of restitution during contact and the latter is compared with estimates based on numerical solutions of the non-linear equation of motion.     

Capillary breakup extensional rheometry (CaBER) on semi-dilute and concentrated polyethyleneoxide (PEO) solutions

Semi-dilute ( $c^\ast < c < c_{\rm e}$ ) as well as concentrated, entangled (c?>?c _e) solutions of PEO yield uniformly thinning, cylindrical filaments in capillary breakup extensional rheometry (CaBER) experiments. Up to c?≈ c _e thinning can be characterized by a single elongational relaxation time λ _E. Comparison with the longest shear relaxation time, λ _S reveals that λ _E/λ _S decreases with increasing concentration or molecular weight according to (c[η])^???4/3. This is attributed to the large deformation the solutions experience during filament thinning. A factorable integral model including a single relaxation time and a Soskey or Wagner damping function accounting for the large deformation in CaBER experiments is used to calculate λ _E/λ _S and provides good agreement with experimental results. Irrespective of concentration or molecular weight a beads-on-a-string structure occurs prior to filament breakup at a diameter ratio D/D ₀?≈ 0.01. This instability is supposed to be closely related to a flow-induced phase separation.     

Existence and construction of quadratic invariants for the equation d2dξ2ν = λ(ξ)ddξν + f(ξ,ν)

If the equation ν_ζζ = λ(ξ)ν_ζ + F(ξ,ν) admits a first integral quadratic in the momentum c., the function F(ξ,ν) is defined; a new procedure is introduced to find the first integral. Among the examples is discussed the existence of quadratic invariants for the equation u″ λu′ = Q(u), where λ is a constant, and for the equation ν_ξ,ξ =βξ^σνⁿ. This last equation admits a first integral, quadratic in ν_ξ if σ = 0, or n = −2σ − 3, or n = −σ − 3. Particular eases are exhibited where no invariant quadratic in ν_ξ is found for the equation ν_ξξ = βξ^σνⁿ but it admits a first integral which is a polynomial of degree 4 or 6 in ν_ξ.     

Phenomenological study of parabolic and spherical indentation of elastic-ideally plastic material

A phenomenological study of parabolic and spherical indentation of elastic ideally plastic materials was carried out by using precise results of finite elements calculations. The study shows that no “pseudo-Hertzian” regime occurs during spherical indentation. As soon as the yield stress of the indented material is exceeded, a deviation from the, purely elastic Hertzian contact behaviour is found. Two elastic–plastic regimes and two plastic regimes are observed for materials of very large Young modulus to Yield stress ratio, E/σ_y. The first elastic–plastic regime corresponds to a strong evolution of the indented plastic zone. The first plastic regime corresponds to the commonly called “fully plastic regime”, in which the average indentation pressure is constant and equal to about three times the yield stress of the indented material. In this regime, the contact depth to penetration depth ratio tends toward a constant value, i.e. h_c/h = 1.47. h_c/h is only constant for very low values of yield strain (σ_y/E lower than 5 × 10^?6) when aE¹/Rσ_y is higher than 10,000. The second plastic regime corresponds to a decrease in the average indentation pressure and to a steeper increase in the pile-up. For materials with very large E/σ_y ratio, the second plastic regime appears when the value of the non-dimensional contact radius a/R is lower than 0.01. In the case of spherical and parabolic indentation, results show that the first plastic regime exists only for elastic-ideally plastic materials having an E/σ_y ratio higher than approximately 2.000.     

Stress singularity due to traction discontinuity on an anisotropic elastic half-plane

In a half-plane problem with x₁ paralleling with the straight boundary and x₂ pointing into the medium, the stress components on the boundary whose acting plane is perpendicular to x₁ direction may be denoted by t₁ = [σ₁₁, σ₁₂, σ₁₃]^T. Stress components σ₁₁ and σ₁₃ are of more interests since σ₁₂ is completely determined by the boundary conditions. For isotropic materials, it is known that under uniform normal loading σ₁₁ is constant in the loaded region and vanishes in the unloaded part. Under uniform shear loading, σ₁₁ will have a logarithmic singularity at the end points of shear loading. In this paper, the behavior of the stress components σ₁₁ and σ₁₃ induced by traction-discontinuity on general anisotropic elastic surfaces is studied. By analyzing the problem of uniform tractions applied on the half-plane boundary over a finite loaded region, exact expressions of the stress components σ₁₁ and σ₁₃ are obtained which reveal that these components consist of in general a constant term and a logarithmic term in the loaded region, while only a logarithmic term exists in unloaded region. Whether the constant term or the logarithmic term will appear or not completely depends on what values of the elements of matrices Ω and Γ will take for a material under consideration. Elements for both matrices are expressed explicitly in terms of elastic stiffness. Results for monoclinic and orthotropic materials are all deduced. The isotropic material is a special case of the present results.     

Propagation of Flames in the Limit of Zero Ignition Temperature

This paper is devoted to the study of planar deflagration flames. The combustion takes place in a gaseous mixture in which N chemical species B ₁,…,B _N are subject to a complex chemical network of R chemical reactions: In the limit of zero ignition temperature, existence of traveling waves for any speed in a range [c ₀,+∞) is proved for exothermic networks. Non-existence is proved for c∈(0,c ^*). A new index argument is introduced which is of independent interest. In the case of Lewis number less than 1 and of non-competitive networks, the set of speeds is exactly the interval [c ₀,+∞) (c ₀?=?c ^*).     

Heat transfer and skin-friction in a turbulent boundary layer under a non-equilibrium longitudinal adverse pressure gradient

The experimental data on the effect of weak and moderate non-equilibrium adverse pressure gradients (APG) on the parameters of dynamic and thermal boundary layers are presented. The Reynolds number based on the momentum thickness at the beginning of the APG region was Re^** = 5500. The APG region was a slot channel with upper wall expansion angles from 0 to 14°. The profiles of the mean and fluctuation velocity components were measured using a single-component hot-wire anemometer. The friction coefficients were determined using two methods, namely, the indirect Clauser method and the direct method of weighting the lower wall region on a single-component strain-gage balance. The heat transfer coefficients were determined by a transient method using an IR camera. It is noticed that in the pressure gradient range realized the universal logarithmic region in the boundary layer profile is conserved. The values of the relative (divided by the parameters in zero gradient flow at the same value of Re^**) friction and heat transfer coefficients, together with the Reynolds analogy factor, are determined as functions of the longitudinal pressure gradient. The values of the relative friction coefficient reduced to c_f/c_f0 = 0.7 and those of the heat transfer to St/St₀ = 0.9. A maximum value of the Reynolds analogy factor (St/St₀)/(c_f/c_f0) = 1.16 was reached for the pressure gradient parameter β = 2.9.     

A strength reliability model by Markov process of unidirectional composites with fibers placed in hexagonal arrays

This paper proposes a strength reliability model based on a Markov process for unidirectional composites with fibers in a hexagonal array. The model assumes that a group of fiber breaking points, a so-called cluster, evolves with increased stress. The cluster evolution process branches because of various fiber-breakage paths. Load-sharing structure of intact fibers around clusters was estimated from geometric and mechanical local load-sharing rules. Composites fracture if a cluster achieves a critical size, so the model expresses a fracture criterion by setting an absorbing state. Next, the author constituted a state transition diagram concerning cluster evolutions of 1-fiber to 7-fiber breaks and analytically solved simultaneous differential equations obtained from the diagram. Results showed that, as critical cluster size increases, slope of the fracture probability distribution is given in a Weibull probability scale as follows: m_c=i×m_f (i, the number of broken fibers in a cluster; m_c and m_f, Weibull shape parameters for fracture probabilities of a critical cluster and fiber strength, respectively). This relation between m_c and m_f had been shown by Smith et al. [Proc. R. Soc. London, A 388 (1983) 353–391], but the present study demonstrated it analytically without any lower tail of the Weibull distribution used in that paper. In addition, the present model can be approximated by a one-state birth model.     

Fracture mechanics applications of absorbed specific fracture energy: Notch and unnotched specimens

The Absorbed Specific Fracture Energy (ASFE)^* is an energy criterion that may be applied to evaluate the embrittlement and fracture properties of low and medium strength structural materials. Some new results are presented to illustrate the application of ASFE, and relating them to the other fracture criteria such as J_1c and K_1c. A comparison of results is made for static and dynamic loading, and the influence of neutron irradiation.