嵌入式超声传感器的混凝土损伤非线性检测研究*

对建筑结构在其生命周期中的损伤状态进行实时监测十分重要,借助埋在混凝土构件内部的压电传感器对结构进行无损检测是一种新型的检测手段。本文将压电传感器嵌入混凝土试件内部,通过超声二次谐波法对信号进行分析处理得到表征材料损伤的非线性参数,以此来监测混凝土的早期强度并对混凝土试件受压和钢筋混凝土梁受弯的不同损伤程度进行检测。结果证明,非线性参数可以反映混凝土养护过程的强度增长情况,也可以表征不同损伤形式下试件的损伤程度。     

Fatigue Life Prediction of a Rubber Mount Based on the Continuum Damage Mechanics

Abstract

Failure analysis and fatigue life prediction are important steps in the design procedure of industrial products to assure the safety and reliability of their components. A new methodology to predict the fatigue life of a rubber mount based on the continuum damage mechanics is proposed in this study. The hyperelastic constitutive model of the natural rubber material in the mount was fitted using the three parameter Mooney-Rivlin model. A damage variable was introduced and the evolution function of cumulative damage in the rubber material was derived. The parameters in the damage function were acquired based on uniaxial tensile tests and fatigue life tests of the natural rubber specimens. Then the finite element analysis (FEA) models of the rubber mount for loads in the X and Y directions were established and the strain contours and the maximum principal strains of the rubber mount under various loads were calculated. The maximum principal strain was used as the fatigue parameter, which was substituted into the natural rubber’s fatigue life damage function to predict the fatigue life of the rubber mount. Finally, the fatigue lives of the rubber mount under various loads were measured on a fatigue test rig to validate the accuracy of the fatigue life prediction method. The test results indicated that the fatigue lives predicted agreed fairly well with the test results and the fatigue prediction method should be applicable to both rubber and other types of components.     

Critical Plane Orientation Influence on Multiaxial High-Cycle Fatigue Assessment

In the present paper, the multiaxial fatigue lifetime of structural components failing in the high-cycle fatigue regime is evaluated by employing the modified Carpinteri-Spagnoli (C-S) multiaxial fatigue criterion based on the critical plane approach. In the above criterion, the critical plane position is linked to averaged principal stress directions through an off-angle 8. Then, the fatigue damage parameter used is determined by a nonlinear combination of an equivalent normal stress amplitude and the shear stress amplitude acting on the critical plane. In the present paper, some modifications of the original expression for the off-angle 8 are implemented in the modified Carpinteri-Spagnoli criterion. In particular, modified expressions recently proposed by Lagoda et al. are in accordance with the assumption originally developed by Carpinteri and co-workers, that is, the off-angle is a function of the ratio between the fatigue limit under fully reversed shear stress and that under fully reversed normal stress. Such expressions can be employed for metals ranging from mild to very hard fatigue behaviour. Some experimental data available in the literature are compared with the theoretical estimations and, only for materials with hard and very hard fatigue behaviour, the modified 8 relationships are shown to yield fatigue lifetime results slightly better than those determined through the original 8 expression.     

Detection of fatigue damage in steel using laser speckle

We investigated a method to detect fatigue damage of steels without contact using laser speckle. In the earlier stage of fatigue in steels, slipbands appear on the surface and microscopic shear strain is stored in the slipbands. The slipbands appear more densely with progress of fatigue damage. When a laser illuminates the surface of the fatigued steel, light intensity distribution of the laser speckle pattern formed by the reflected light changes with the change of surface properties caused by slipbands. It has been clarified that the width of the speckle pattern broadens corresponding to spatial frequency distribution of the surface profile and thus it is presumed that speckle pattern broadens with increase of slipband density. This shows that we can detect fatigue damage by observing the laser speckle pattern on material surface. The method presented in this paper is based on this phenomenon. We observed change of the speckle pattern during fatigue loading under constant stress amplitude using a steel specimen and the relation between speckle pattern, number of loading cycles and also magnitude of loading was considered. We investigated the possibility of detection of fatigue damage using this method and also proposed a method to estimate fatigue life by observing change tendency of the speckle pattern depending on the number of loading cycles in the earlier stage of fatigue before crack initiation.     

On-line detection of fatigue cracks using an automatic mode tracking technique

Experimental fatigue tests usually require large testing times. In addition to the resulting increased time-to-market, the large fatigue test time also implies that any structural health monitoring technique that is used should be automatic. When using the modal parameters as damage indicators, an important amount of user interaction is still needed to separate physical poles from computational ones. In this paper, an experimental framework will be developed to automatically track the health of the structure on-line with the performance of fatigue tests. The modal parameters are tracked using a combination of the maximum likelihood estimator and an auto-regressive model. Since confidence levels on the modal parameter are available it is possible to detect if damage is present. In addition, the quasi-static stiffness with computed confidence levels is also used as a damage indicator. The proposed techniques are demonstrated on a steel beam with a propagating fatigue crack.     

Baseline-free estimation of residual fatigue life using a third order acoustic nonlinear parameter

Prediction of crack growth and fatigue life estimation of metals using linear/nonlinear acousto-ultrasound methods is an ongoing issue. It is known that by measuring nonlinear parameters, the relative accumulated fatigue damage can be evaluated. However, there is still a need to measure two crack propagation states to assess the absolute residual fatigue life. A procedure based on the measurement of a third-order acoustic nonlinear parameter is presented to assess the residual fatigue life of a metallic component without the need of a baseline. The analytical evaluation of how the cubic nonlinear-parameter evolves during crack propagation is presented by combining the Paris law to the Nazarov-Sutin crack equation. Unlike other developed models, the proposed model assumes a crack surface topology with variable geometrical parameters. Measurements of the cubic nonlinearity parameter on AA2024-T351 specimens demonstrated high sensitivity to crack propagation and excellent agreement with the predicted theoretical behavior. The advantages of using the cubic nonlinearity parameter for fatigue cracks on metals are discussed by comparing the relevant results of a quadratic nonlinear parameter. Then the methodology to estimate crack size and residual fatigue life without the need of a baseline is presented, and advantages and limitations are discussed.     

Modeling nonlinearities of ultrasonic waves for fatigue damage characterization: Theory,simulation, and experimental validation

A dedicated modeling technique for comprehending nonlinear characteristics of ultrasonic waves traversing in a fatigued medium was developed, based on a retrofitted constitutive relation of the medium by considering the nonlinearities originated from material, fatigue damage, as well as the “breathing” motion of fatigue cracks. Piezoelectric wafers, for exciting and acquiring ultrasonic waves, were integrated in the model. The extracted nonlinearities were calibrated by virtue of an acoustic nonlinearity parameter. The modeling technique was validated experimentally, and the results showed satisfactory consistency in between, both revealing: the developed modeling approach is able to faithfully simulate fatigue crack-incurred nonlinearities manifested in ultrasonic waves; a cumulative growth of the acoustic nonlinearity parameter with increasing wave propagation distance exists; such a parameter acquired via a sensing path is nonlinearly related to the offset distance from the fatigue crack to that sensing path; and neither the incidence angle of the probing wave nor the length of the sensing path impacts on the parameter significantly. This study has yielded a quantitative characterization strategy for fatigue cracks using embeddable piezoelectric sensor networks, facilitating deployment of structural health monitoring which is capable of identifying small-scale damage at an embryo stage and surveilling its growth continuously.     

循环温度疲劳作用下粘接界面损伤的非线性超声评价

材料损伤以及性能退化与超声波的非线性效应密切相关.为研究循环温度疲劳作用下粘接界面的损伤情况,本文采用超声波透射法,研究了6061型铝合金/改性丙烯酸酯胶粘接界面的声学非线性系数随高温、低温循环次数的变化情况.结果表明,在高温循环疲劳作用的初始阶段,试件的非线性系数变化不明显,但随着高温循环次数的不断增加,非线性系数随循环次数的变化十分明显;对于低温循环疲劳作用的初始阶段,试件的非线性系数迅速增大,随着循环次数的增加,其值增速减缓.在低温循环疲劳寿命的后期,试件的非线性系数随循环次数的增加而继续增大.进一步的讨论结果表明,胶层三阶弹性常数的变化是造成高温循环疲劳时非线性系数变化的主要原因,而对于低温循环疲劳,粘接界面拉伸刚度的变化是引起非线性系数变化的主要原因.     

Finite element modelling for fatigue stress analysis of large suspension bridges

Fatigue is an important failure mode for large suspension bridges under traffic loadings. However, large suspension bridges have so many attributes that it is difficult to analyze their fatigue damage using experimental measurement methods. Numerical simulation is a feasible method of studying such fatigue damage. In British standards, the finite element method is recommended as a rigorous method for steel bridge fatigue analysis. This paper aims at developing a finite element (FE) model of a large suspension steel bridge for fatigue stress analysis. As a case study, a FE model of the Tsing Ma Bridge is presented. The verification of the model is carried out with the help of the measured bridge modal characteristics and the online data measured by the structural health monitoring system installed on the bridge. The results show that the constructed FE model is efficient for bridge dynamic analysis. Global structural analyses using the developed FE model are presented to determine the components of the nominal stress generated by railway loadings and some typical highway loadings. The critical locations in the bridge main span are also identified with the numerical results of the global FE stress analysis. Local stress analysis of a typical weld connection is carried out to obtain the hot-spot stresses in the region. These results provide a basis for evaluating fatigue damage and predicting the remaining life of the bridge.     

化学增透膜激光疲劳损伤效应

疲劳效应是诱导高功率固体激光装置中光学元件激光损伤的因素之一,目前对SiO₂化学增透膜激光诱导疲劳损伤的研究鲜见报道。基于此,本文采用单一激光能量多发次辐照和多梯度激光能量多发次辐照两种不同的激光辐照方式,研究1064 nm化学增透膜层的激光疲劳损伤效应及特征。研究结果表明,在单一激光能量多发次脉冲激光辐照下,膜层最易发生疲劳损伤; 采用多梯度激光能量多发次辐照的方式,可以有效地提升膜层的损伤阈值,进而提升膜层的抗激光疲劳损伤性能。     

Non-equilibrium statistical theory about microscopic fatigue cracks of metal in magnetic field

This paper develops the non-equilibrium statistical fatigue damage theory to study the statistical behaviour of micro-crack for metals in magnetic field. The one-dimensional homogeneous crack system is chosen for study. To investigate the effect caused by magnetic field on the statistical distribution of micro-crack in the system, the theoretical analysis on microcrack evolution equation, the average length of micro-crack, density distribution function of micro-crack and fatigue fracture probability have been performed. The derived results relate the changes of some quantities, such as average length, density distribution function and fatigue fracture probability, to the applied magnetic field, the magnetic and mechanical properties of metals. It gives a theoretical explanation on the change of fatigue damage due to magnetic fields observed by experiments, and presents an analytic approach on studying the fatigue damage of metal in magnetic field.     

An energy-equilibrium model for complex stress effect on fatigue crack initiation

Based on Tanaka and Mura’s fatigue model and Griffith theory for fracture,an energy-equilibrium model was proposed to explain the complex stress effect on fatigue behavior.When the summation of the elastic strain energy release and the stored strain energy of accumulated dislocations reach the surface energy of a crack,the fatigue crack will initiate in materials.According to this model,for multiaxial stress condition,the orientation of the crack initiation and the initiation life can be deduced from the energy equilibrium equation.For the uniaxial fatigue loading with mean stress,the relation between the maximum stress or the minimum stress and the stress amplitude is in agreement with an ellipse equation on the constant life diagram.If the ratio of the mean stress to stress amplitude is less than a critical value-0.17,and the stress amplitude keeps constant,the fatigue crack initiation life will decrease with the increase of the compress mean stress.In this model,the mean stress does not cause damage accumulation with the fatigue cycles in crack initiation.For this reason,the loading sequence of different load levels would induce the cumulative damage to deviate from the Palmgren-Miner cumulative damage rule.The procedure of estimating the damage under random loading is also discussed.     

Computed speckle decorrelation (CSD) for the study of fatigue damage

A video-based laser speckle technique has been developed for noncontact analysis of fatigue in situ and at speeds approaching video frame rates. This technique, computed speckle decorrelation (CSD), makes use of the speckle decorrelation associated with surface deformation. It is a method of full field inspection which both locates fatigue damage sites and measures damage severity. In its current application, CSD has been used to study the fatigue deformation progression in reverse bending fatigue of a cylindrically notched aluminum specimen. However, film based studies have shown the usefulness of laser speckle decorrelation to analyze fatigue deformation of thick graphite/epoxy composite materials as well. With the development of the CSD method it will now be possible to examine in greater detail the progression of fatigue damage in these materials, allowing a much faster and more quantitative analysis than was previously available.     

Some analytical expressions to measure the accuracy of the “equivalent von Mises stress” in vibration multiaxial fatigue

The “equivalent von Mises stress” (EVMS) was first proposed in 1994 by Preumont and co-workers as a frequency domain reformulation of von Mises stress, for the fatigue analysis of vibrating structures under multiaxial random stresses. The EVMS criterion is a simple, but very powerful tool to estimate fatigue damage with time domain analysis of simulated stress histories, or frequency domain evaluation by spectral methods. Despite its simplicity, the EVMS criterion is based on some inherent assumptions, which may lead to inaccurate damage estimations in some particular conditions (e.g. materials with very different axial/bending and torsion S–N curves). This paper aims to derive some analytical expressions to measure the accuracy of EVMS criterion for various combinations of material fatigue properties and loading conditions (e.g. combined axial/bending and torsion loadings). These expressions constitute an original contribution, as similar analytical approaches have not been proposed in literature. The accuracy of EVMS approach is then tested with typical material fatigue properties from literature. The range of applicability of EVMS criterion is then be identified for specified intervals and combinations of S–N parameters.     

Fatigue life prediction for high‐heat‐load components made of GlidCop by elastic‐plastic analysis

A procedure to predict the fatigue fracture life of high‐heat‐load components made of GlidCop has been successfully established. This method is based upon the Manson–Coffin equation with a cumulative linear damage law. This prediction was achieved by consolidating the results of experiments and analyses, and considered the effects of environment and creep. A low‐cycle‐fatigue test for GlidCop was conducted so that environment‐dependent Δ?_t–N_f diagrams for any temperature could be prepared. A special test piece was designed to concentrate the strain in a central area locally, resulting in the low‐cycle‐fatigue fracture. The experiments were carried out by repeatedly irradiating a test piece with an electron beam. The results of the experiment confirmed that the observed fatigue life was within a factor of two when compared with the predicted fatigue life, yet located on the safer side.     

镁合金疲劳早期非线性超声在线检测实验研究

材料力学性能早期退化在微观结构上表现为位错和晶带滑移等缺陷的变化,在超声波检测中表现为高次谐波的产生。发展了一套在材料疲劳实验机上直接任线测量超声非线性系数的实验系统,在相同条件下测量了同一试件作不同输入电压下的二次谐波和基波幅度,二次谐波幅度和基波幅度平方的线性相关系数r=0.9996,表明实验系统是可靠的。同时利用该系统进行了三组不同加载应力的镁合金试件疲劳在线非线性超声检测实验。实验结果表明,在疲劳寿命的55%之前,超声非线性系数对疲劳加载周数具有很高的灵敏度。因此,利用超声非线性系数可以很好地表征镁合金的疲劳早期退化。另外在中低周疲劳范围内,加载应力的大小以及拉-拉和拉压疲劳模式的变化对实验结果没有明显的影响。     

Effects of pre-placed coating thickness on thermal fatigue resistance of cast iron with biomimetic non-smooth surface treated by laser alloying

In order to enhance the thermal fatigue resistance of gray cast iron with biomimetic non-smooth surface further, studies on laser alloying of Cr powder with different pre-placed coating thickness were performed to change both the composition and the microstructure of non-smooth unit. Additionally, the optimization of coating thickness was done based on the content of Cr in alloyed zone and the thermal fatigue behaviors of non-smooth samples. The results indicated that there was a critical coating thickness which corresponded to the increase of Cr content in alloyed zone under a definitive laser processing conditions, and the critical thickness was 0.3 mm in this paper. Any coating thicker than 0.3 mm would lead to the waste of alloying powder. The thermal fatigue resistance of non-smooth samples was better than that of smooth sample. In addition among all the non-smooth samples, the sample which was treated by the laser alloying of Cr had superior resistance to thermal fatigue compared with laser melting treated samples. And the thermal fatigue resistance increased with increasing of Cr content in alloyed zone which was caused by pre-placed coating thickening.     

列车外圆弹簧疲劳损伤的非线性超声测试

进行了列车外圆弹簧在疲劳载荷作用下所产生损伤的非线性超声测试。对列车外圆弹簧进行疲劳加载,利用专门的非线性超声测试系统激发和接收透过弹簧的超声纵波。在相应的信号处理后,建立了声学非线性系数与弹簧疲劳次数之间的关系。实验结果表明,当疲劳次数小于150万次时,由于弹簧材料内部位错、滑移带等微观缺陷还没有形成足以产生显著非线性的积累,该非线性系数增长不明显;当疲劳次数达到150万次至300万次之间的疲劳响应期时,非线性系数增加明显,表明弹簧材料的内部损伤快速增加;当疲劳次数超过300万次时,弹簧材料的内部损伤积累速度减缓,非线性系数增加放缓。该研究表明列车外圆弹簧的疲劳损伤程度与其声学非线性系数直接相关,利用该方法可以为材料和结构早期力学性能退化的检测和评价提供一种有效的途径。