Affected depth approach to determine the fatigue strength of materials containing surface defects

This paper explains a novel methodology to determine the High Cycle Fatigue (HCF) reliability of materials with defects. A defect was represented by a semi-spherical void situated at a specimen surface subjected to periodic loading. Then, the Finite Element (FE) method was carried out to find out the stress distribution near the defects for diverse sizes and diverse loadings. The Crossland stress change is studied and interpolated by a mathematical function depending on fatigue limits, defect radius, and profundity from the defect tip. The HCF strength of defect material is computed by the “stress strength” approach via the Monte Carlo sampling. This approach leads to determine Kitagawa–Takahashi diagrams, for a definite reliability, of materials with defects. The calculated HCF reliabilities agree well with fatigue tests. Obtaining Kitagawa–Takahashi diagrams with reliability level permits the engineer to be engaged in an endurance problem to compute the defective fatigue lives in safe and efficient process. As a final point, we discuss the sensitivity effects of defect size, defect free fatigue limits, affected depth, and load amplitude to envisage the fatigue reliability of materials with defects.     

孔洞缺陷对3D打印Ti-6Al-4V合金疲劳试样应力分布的影响

3D打印金属技术因其个性化及可用于加工复杂零件等显著优点,在医用骨植入体领域得到了快速发展,但3D打印金属材料的孔洞缺陷所引起的应力集中现象严重降低了其疲劳强度,限制了3D打印生物金属材料的运用。本文针对3D打印Ti-6Al-4V合金超声疲劳试样,分析了Micro CT扫描试样得到的三维图像,获得了试样内孔洞缺陷的数量与体积;选择体积分数占比最大的孔洞,采用有限元方法分析了三种不同孔洞分布形式下的局部应力集中现象。研究发现,因空间位置的不同,独立的孔洞、接近自由表面的孔洞、相邻的孔洞三种不同孔洞的分布情况的应力集中系数差异显著。研究结果在一定程度上解释了目前EBM技术打印Ti-6Al-4V合金的孔洞缺陷如何对材料受力后的局部应力情况产生影响。     

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。     

Fatigue crack initaition and propagation from hole defects

The aim of this study is to investigate the interaction of two hole defects affecting fatigue crack initiation life and propagation behavior. The location of two hole defects was characterized by an angle of alignment and the distance between the centers of two hole defects. The fatigue cracking behavior is studies under bending for AI 5086. When defects are located close to each other, the fatigue crack initiation lives are varied with their relative locations. In the experiments, the area of the local plastic stratin strongly played a role in the fatigue crack initiation lives. Therefore, the authors introduce a parameter which contains the plastic deformation are at stress concentrations and proposed a fatigue crack initiation life prediction curve. In addition, the directions and propagation rates of fatigue cracks initiated at two hole defects were studied experimentally.     

Application of photoelasticity to a weld-penetration problem

The need for more information on the “initiation period” in fatigue tests of weld specimens with penetration defects is discussed and the literature which relates the elasticity stress-concentration factor and Irwin's stress-intensity factor is reviewed. A series of photoelasticity tests on two-dimensional plane-stress models of typical penetration defects is described. In particular a method for casting “ready to use” very narrow defects is explained. The results are presented in a graph of stress-concentration factor against defect length. This graph has a “knee” at defect length-to-plate thickness ratios around 0.2. Below the “knee”, the stress-concentration factor changes very little with changes in defect length but, for lengths beyond the knee, i.e., ratios larger than 0.2, the stress concentrations increase linearly with defect length. It is concluded that such a critical defect length should have a strong effect on fatigue life of defective welds and that it may constitute a first approach to the specification of an “acceptable” level of penetration defects for production processes.     

FATIGUE LIFE PREDICTION OF SUS 630 （H900） STEEL UNDER HIGH CYCLE LOADING

The fatigue life prediction of high strength steel SUS 630 （H900） under high cycle loading is conducted with consideration of a characteristic fatigue length of material. Based on the WShler curve of smooth materials, a modified method for fatigue life prediction is approached. The characteristic fatigue length of material under cyclic loading is associated with the polycrystalline material. Rather than the stress at a point, the average stress within the characteristic fatigue length is implemented for the fatigue life prediction. The method can be applied to both the smooth and the defected material. The fatigue life prediction is also verified experimentally by specimens with various small circular holes. Through the comparison, it is found that the method can be adopted to predict the fatigue lives with different size effects.     

A Maximum Likelihood Method for Estimating Probabilistic Strain Amplitude-Fatigue Life Curves

The fatigue lives of materials and structures at different strain levels show heteroscedasticity. In addition, when the number of test specimens is insufficient, the fatigue strength coefficient and fatigue ductility coefficient of the fitting parameters in the total strain life equation may not have definite physical significance. In this work, a maximum likelihood method for estimating probabilistic strain amplitude-fatigue life curves is presented based on the fatigue lives at different strain levels. The proposed method is based on the general basic assumption that the logarithm of fatigue life at an arbitrary strain level is normally distributed. The relationship among the parameters of total strain life equation, monotonic ultimate tensile stress and percentage reduction of area is adopted. The presented approach is finally illustrated by two applications. It is shown that probabilistic strain amplitude-fatigue life curves can be easily estimated based on the maximum likelihood method. The results show that fatigue lives at different strain levels have heteroscedasticity and the values of fatigue strength coefficient and fatigue ductility coefficient obtained by the proposed method are close to those of the true tensile fracture stress and true tensile fracture strain.     

焊趾表面裂纹的形态发展曲线与疲劳寿命预测

以作者建立的焊地椭圆表面裂纹应力强度因子数据库以及复杂应力场中焊践半随圆表面裂纹前缘应力强度因子分布计算的基本模式法为基础上,给出了复杂应力场中焊践表面表纹在疲劳扩展过程中形态变化规律及寿命的工程分析方法。     

COUPLING EFFECTS OF VOID SHAPE AND VOID SIZE ON THE GROWTH OF AN ELLIPTIC VOID IN A FIBER-REINFORCED HYPER-ELASTIC THIN PLATE

The growth of a prolate or oblate elliptic micro-void in a fiber reinforced anisotropic incompressible hyper-elastic rectangular thin plate subjected to uniaxial extensions is studied within the framework of finite elasticity. Coupling effects of void shape and void size on the growth of the void are paid special attention to. The deformation function of the plate with an isolated elliptic void is given, which is expressed by two parameters to solve the differential equation. The solution is approximately obtained from the minimum potential energy principle. Deformation curves for the void with a wide range of void aspect ratios and the stress distributions on the surface of the void have been obtained by numerical computation. The growth behavior of the void and the characteristics of stress distributions on the surface of the void are captured. The combined effects of void size and void shape on the growth of the void in the thin plate are discussed. The maximum stresses for the void with different sizes and different void aspect ratios are compared.     

铁电陶瓷电致疲劳失效的研究进展

铁电陶瓷是具备力电转换功能的典型高技术材料.本文概述铁电陶瓷电致疲劳失效的研究进展.首先介绍电致疲劳的定义和特点,然后讨论电致疲劳失效在不同尺度下的表现行为,包括宏观尺度下裂纹的疲劳扩展;细观尺度下裂纹的萌生;微观尺度下点缺陷在循环电场下的积聚.随即阐述了铁电陶瓷在循环电场下缺陷汇聚的理论分析,运用微结构演化方法计算了单个孔洞随畴界的移动距离,推导了循环电场下铁电陶瓷内点缺陷浓度的演化方程,给出了点缺陷浓度与其汇聚程度之间的定量关系,从而提出了贯通不同尺度的铁电陶瓷电致疲劳失效机理.      

Reducing the effects of rivet holes on fatigue life by adhesive bonding

Rivet holes are potential sites for fatigue crack initiation in aircraft structures. Several methods for improving the life of such details were investigated including coating the surface of the hole with adhesive, cold-expansion of the holes, the insertion of close-fit rivets and the use of adhesively-bonded rivets. Of the various techniques examined, only that involving adhesively-bonded rivets provided any significant improvements in fatigue life. It resulted in a reduction in fatigue crack propagation rate of about 50% compared with that for specimens incorporating open holes.A finite element analysis indicated that adhesive bonding significantly reduces both the local stress concentration at the hole and the stress intensities at the crack tips, thus retarding crack initiation and reducing fatigue crack propagation rates. However, the effective reduction in stress intensity resulting from bonding (about 17%) is much less than the 50% predicted by the finite element analysis. This discrepancy is attributed mainly to shortcomings in the model for defining the characteristics and behaviour of the adhesive.     

A parametric-experimental study of void growth in superplastic deformation

Substantial void growth in metals constitutes a problem in many industrial operations that utilize superplastic deformation. This is because of the likelihood of material failure due to such growth. Hence, there is a need to study void growth mechanisms in an effort to understand the parameters governing it. In this work, numerical and experimental studies of void growth, and the parameters that affect it, in a superplastically deforming (SPD) metal have been performed. In the numerical studies, using the finite-element method, a 1×2 sized thin plate (i.e. plane stress conditions) of a viscoplastic material with pre-existing holes has been subjected to a constant extension rate. The experimental studies were performed under similar conditions to the numerical ones and provided for qualitative comparison. The parameters affecting void growth in SPD are: m (the strain-rate sensitivity), void size (i.e. diameter) and the number (density) of existing voids. The results showed that increased m values produced strengthening and decreased the rate of void growth. In addition, larger initial void size (or, equivalently, a larger initial void fraction) had the effect of weakening the specimen through causing accelerated void growth. Finally, multiple holes had the effect of increasing the metal ductility by reducing the extent of necking and its onset. This was realized through diffusing the plastic deformation at the different hole sites and reducing the stress concentration. The numerical results were in good qualitative agreement with the experiment and suggested the need to refine existing phenomenological void growth models to include the dependence on the void fraction.     

一种FRP累积损伤模型及其在结构疲劳寿命估算中的应用

推荐了一种应变损伤累积模型，能够考虑单向板面内多轴应力和平均应力的影响。只需要单向板在确定应力比下的若干典型疲劳试验结果，就可以预测相同材料体系多向层压结构在不同应力比的循环载荷下的疲劳寿命，有助于降低试验成本和工作量。研究了适用于多向层压结构剩余强度估算和疲劳寿命预测的步骤和程序。针对碳纤维／树脂基T300／QY8911复合材料，试验测定了三组典型单轴循环应力（[0]16拉－拉、[90]16拉－拉和[0/90]4S剪－剪）下的S－N曲线。以此为输入，预测四种多向铺层板在各种拉－拉循环应力下的疲劳寿命，寿命预测结果和相应的试验结果吻合良好。采用了保持计算和试验的载荷／强度比相对等值的方法来近似抵消层合效应对疲劳寿命的影响。强调了进一步发展能够定量估计层间应力影响与分层扩展过程的疲劳损伤模型的重要性。     

Thermal fatigue assessment of components made with particulate polymer composites

Many appliance materials are made of PMMA/Si acrylic casting dispersion. In these situations, failure can occur by thermal fatigue induced by severe temperature variations such as alternating flows of cold and hot water. This paper is concerned with the numerical analysis of the thermal stresses in three composites with different volume fractions of filler and particle size. Their trade marks are Asterite, Amatis and Ultra-quartz. Cosmos/M finite element method software was used to study the influence of the cold and hot water temperatures as well as the time of interruption of water flow in the transition between hot and cold water on thermal stresses. Residual stresses were measured and superimposed to thermal stress in fatigue analysis. Typical defects in the corner of holes produced by drilling were predicted using experimental fatigue lives and da/dN curves. Based on predicted defects thermal fatigue assessment of commercially available sinks made with the three materials mentioned earlier was done by taking into account the influence of both cyclic thermal and static residual stresses induced by the manufacturing process.     

Plastic stress and acoustic emission as predictors of fatigue life

The high rate of acoustic emission from AISI E4340 annealed steel when it is stressed can be used to accurately indicate the yield stress. Predictive equations for the fatigue life of AISI E4340 annealed steel have been developed by the use of “Multiple Classification Analysis” and “Stepwise Regression” computer programs based on an experimental study of 175 specimens. The acoustic emission from the fatigue specimens was investigated prior to fatiguing, but no parameter of the emission was found to correlate significantly with fatigue life. The high-rate emission which occurs at yield is found to be useful in determining the value of the yield stress. The value of the stress into the plastic range determined in this manner was defined by both statistical approaches as the best predictor of fatigue life. The fatigue stress level was rejected as a lesser predictor. Surface finish in the range of 90 to 350 μin. was found to have little correlation with fatigue life of this material.     

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.     

Effects of grain boundary on irradiation-induced zero-dimensional defects in an irradiated copper

Grain boundaries(GBs) can serve as effective sinks for radiation-induced defects, thus notably influencing the service performance of materials. However, the effect of GB structures on the zero-dimensional defects induced by irradiation has not been fully elucidated. Here, the evolution of cascade collision in the single-crystal(SC),bicrystalline(BC), and twinned crystalline(TC) copper is studied by atomic simulations during irradiation. The spatial distributions of vacancies and interstitials a...     

Reinforcement of perforated metal sheets by thermal shock with laser beams

A quantitative study was conducted on the improvement of load-bearing capacity and fatigue life of a thin aluminum sheet containing a small hole by means of thermal shock generated by a pulsed laser. A finite-element computer code based on the thermoelastic-plasticity theory was used to assess the distributions of temperature and residual stresses in the affected region. Analytical results were verified by the measured values from various techniques including the X-ray diffraction method for the residual-stress measurements. The improvement of fatigue life of the sheet metals resulting from this thermal shock process has been demonstrated by tests and correlates well with a postulated empirical model with the calculated induced residual stress.     

压电体中考虑表面效应时开裂孔洞的断裂特征

研究了反平面机械载荷和面内电载荷作用下压电体中考虑表面效应时孔边双裂纹问题的断裂特征。基于Gurtin-Murdoch表面理论模型,通过构造映射函数,利用复势电弹理论获得了应力场和电位移场的闭合解答。给出了裂纹尖端应力强度因子、电位移场强因子和能量释放率的解析解。讨论了开裂孔洞几何参数和施加力电载荷对电弹场强因子和能量释放率的影响。