In‐phase and out‐of‐phase thermomechanical fatigue behavior of 4Cr5MoSiV1 hot work die steel cycling from 400 °C to 700 °C

The hysteresis loops, stress and strain behavior, lifetime behavior and fracture characteristic of 4Cr5MoSiV1 hot work die steel at a wide range of mechanical strain amplitudes (from 0.5% to 1.3%) during the in‐phase (IP) and out‐of‐phase (OP) thermomechanical fatigue (TMF) tests cycling from 400 °C to 700 °C under full reverse strain‐controlled condition were investigated. Stress‐mechanical strain hysteresis loops of 4Cr5MoSiV1 steel are asymmetric, and stress reduction appears at high‐temperature half cycles owing to a decrease in strength with increasing temperature. 4Cr5MoSiV1 steel always exhibits continuous cyclic softening for both types of TMF tests, and the cyclic softening rate is larger in OP loading condition. OP TMF life of 4Cr5MoSiV1 steel is approximately 60% of IP TMF life at the same mechanical strain amplitude and maximum temperature. Lifetime determined and predicted in both types of TMF tests is adequately described by the Ostergren model. Fracture surfaces under IP TMF loading display the striation and tear ridge, showing quasi‐cleavage characteristics, and the cracks are less but longer. However, fracture surfaces under OP TMF loading mainly display the striation and dimple characteristics, and the cracks are more and shorter.     

Towards improved ODS steels: A comparative high‐temperature low‐cycle fatigue study

Within the frame of this work, the mechanical behaviour of a bimodal ferritic 12Cr‐ODS steel as well as of a ferritic‐martensitic 9Cr‐ODS steel under alternating load conditions was investigated. In general, strain‐controlled low‐cycle fatigue tests at 550°C and 650°C revealed similar cyclic stress response. At elevated temperatures, the two steels manifest transitional stages, ie, cyclic softening and/or hardening corresponding to the small fraction of the cyclic life, which is followed by a linear cyclic softening stage that occupies the major fraction of the cyclic life until failure. However, it is clearly seen that the presence of the nano‐sized oxide particles is certainly beneficial, as the degree of cyclic softening is significantly reduced compared with non‐ODS steels. Besides, it is found that both applied strain amplitude and testing temperature show a strong influence on the cyclic stress response. It is observed that the degree of linear cyclic softening in both steels increases with increasing strain amplitude and decreasing test temperature. The effect of temperature on inelastic strain and hence lifetime becomes more pronounced with decreasing applied strain amplitude. When analysing the lifetime behaviour of both ODS steels in terms of inelastic strain energy calculations, it is found that comparable inelastic strain energies lead to similar lifetimes at 550°C. At 650°C, however, the higher inelastic strain energies of 12Cr‐ODS steel result in significant lower lifetimes compared with those of the 9Cr‐ODS steel. The strong degradation of the cyclic properties of the 12Cr‐ODS steel is obviously linked to the fact that the initial hardening response appears significantly more pronounced at 650°C than at 550°C. Finally, the obtained results depict that the 9Cr‐ODS steel offers higher number of cycles to failure at 650°C, compared with other novel ODS steels described in literature.     

Experimental characterisation of a CuAg alloy for thermo‐mechanical applications. Part 2: Design strain‐life curves estimated via statistical analysis

Strain‐life fatigue data on copper alloys, especially type CuAg, are seldom available in the literature. This work fills this gap by estimating the strain‐life curves of a CuAg alloy used for thermo‐mechanical applications, from isothermal low‐cycle fatigue tests at 3 temperatures (room temperature, 250°C, 300°C). Regression analysis is used to estimate the median fatigue curves at 50% survival probability. The comparison of median curves with the Universal Slopes Equation model, calibrated on monotonic tensile properties, shows a fairly good agreement. Design strain‐life curves with a lower failure probability and given confidence are estimated by several approximate statistical methods (“Equivalent Prediction Interval,” univariate tolerance interval, Owen's tolerance interval for regression). When higher survival probabilities are considered, the results show a marked decrease in the allowable design strain at a prescribed fatigue life. The suggested procedure thus improves the durability analysis of components loaded thermo‐mechanically.     

Optimisation methods for the determination of cyclic material parameters from strain controlled uniaxial fatigue tests

Four new methods are presented for the determination of cyclic strain-life curves according to Manson/Coffin/Basquin/Morrow and of cyclic stress–strain curves according to Ramberg/Osgood from results of strain controlled uniaxial fatigue tests. The material parameters are assessed by combined linear regressions of linearised parts of these curves with the method of least squares either in strain–stress-life space or in stress–strain and strain-life planes. The compatibility terms are applied as constraints. Experimental data from fourteen test series of magnesium die-casting alloys AE42, AM50, and AZ91 at different elevated temperature levels between 30 °C and 140 °C is used exemplarily. The four new methods and two methods known from literature, which lack combined linear regression, are valuated with six different measures, which are based on the remaining absolute deviation. The comparison shows that the method that combines the linear regressions of the plastic part of the cyclic stress–strain curve and the elastic and plastic part of the strain-life curve in an optimisation leads to the best results.     

Einfluss von Temperatur und Vorverformung auf das plastische Werkstoffverhalten von modernen Karosseriestählen

Influence of temperature and prestraining on the plastic material behaviour of modern sheet steels for autobody applications Within the scope of a common research project of the automotive and steel industry, characteristic values describing the plastical behaviour of 20 sheet steels have been determined. In detail, quasistatic tensile tests at the testing temperatures ‐40 °C, 23 °C and 100 °C were carried out to obtain flow curves for the as delivered materials as well as for steels after a defined prestraining or heat treatment. Additionally, sheet metal testing led to forming limit diagrams and limiting drawing ratios including the working ranges for deep drawing. The results of the tensile tests showed significant differences between steel groups with regard to their strain hardening behaviour, which can be described by the ratio of yield and tensile strength R_p0,2/R_m or the Θ_IV‐value, and their temperature sensitivity. Within one steel group, consisting of steels with similar strain hardening behaviour, it might be possible to determine flow curves of one steel in a defined condition in order to calculate the flow curves of other steels with different strength. An advantage would be a lesser number of experimental tests which have to be performed in order to supply reliable input data for numerical material and component modelling.     

Werkstoffverhalten unter zügiger elastischer Beanspruchung

Material properties by continuous elastic straining Within the scope of a common research project of the steel and automotive industry, 20 sheet steels have been investigated to obtain input data for FE‐analysis. In detail, characteristical elastic, plastic and fatique values were determined by several testing institutes for a period of 3 years. Knowledge of dependency of Young’s modulus from temperature and orientation is important for spring back at the press shop and stiffness of parts for automotive. Young’s modulus was determined by tensile tests in delivered state, after prestraining, heat treatment at room temperature and –40 °C and 100 °C. Young’s modulus is dependent from the orientation to rolling direction and can be classified in groups. Young’s modulus of ferritic steels is decreased about 10 % by prestraining of 2 % but recovered after annealing at 170 °C. Temperature dependency well known from non destructive tests are confirmed.     

Faser‐ und drahtverstärkte Kupferlegierungen als Wärmesenke für Fusionsreaktoren

Fibre and wire reinforced copper alloys as heat sinks for fusion reactors The CuCr1Zr alloy is used in existing experimental fusion reactors and planned to be used as a heat sink in ITER because of his mechanical properties and thermal conductivity (at 20 °C 310–330 W/m/K). Because of aging this dispersion‐hardened alloy is limited in use to temperatures below 450 °C. A possibility to increase the service temperature (the aim is 550 °C) is to reinforce the alloy with SiC‐fibres or W‐wires. With the aid of SiC (SCS‐6) fibres and W‐wires (diameter ～150 μm for both) coated with the CuCr1Zr‐alloy, Cu‐MMCs are produced and their properties (tensile strength, thermal conductivity, fibre/matrix interface properties) are determined. Processing (Hot Isostatic Pressing) causes the alloy to age, making an additional heat treatment necessary in order to optimize the properties. The tensile strength of the different Cu‐MMCs was determined as a function of the volume content of the reinforcements. Tensile strength rises with increasing volume fraction of fibres (or wires) and reaches e.g. 1000 MPa for a SiC‐fibre volume fraction of 24 % or a W‐wire volume fraction of 27 %. Measurements of the thermal conductivity, performed by laser flash, show that the thermal conductivity is reduced with increasing fibre volume fraction (e.g. 200 W/m/K for a fibre volume fraction of 30 %). The W‐wire reinforced CuCr1Zr alloy has been selected because of its better thermal conductivity and interfacial properties to estimate the potential of this Cu‐MMC in a first design study of heat sinks on the basis of different divertor construction types.     

Ratcheting‐fatigue behaviour of bainite 2.25Cr1MoV steel with tensile and compressed hold loading at 455°C

The ratcheting behaviour of a bainite 2.25Cr1MoV steel was studied with various hold periods at 455°C. Particular attention was paid to the effect of stress hold on whole‐life ratcheting deformation, fatigue life, and failure mechanism. Results indicate that longer peak hold periods stimulate a faster accumulation of ratcheting strain by contribution of creep strain, while double hold at peak and valley stress has an even stronger influence. Creep strains produced in peak and valley hold periods are noticeable and result in higher cyclic strain amplitudes. Dimples and acquired defects are found in failed specimen by microstructure observation, and their number and size increase under creep‐fatigue loading. Enlarged cyclic strain amplitude and material deterioration caused by creep lead to fatigue life reduction under creep‐fatigue loading. A life prediction model suitable for asymmetric cycling is proposed based on the linear damage summation rule.     

Experimental characterisation of a CuAg alloy for thermo‐mechanical applications. Part 1: Identifying parameters of non‐linear plasticity models

Despite the wide use of copper alloys in thermo‐mechanical applications, there is little data on their cyclic plasticity behaviour, particularly for CuAg alloys. This prevents the behaviour of the materials from being correctly described in numerical simulations for design purposes. In this work CuAg0.1 alloy used for thermo‐mechanical applications was tested by strain‐controlled cyclic loading at 3 different temperatures (room temperature, 250°C, 300°C). In each test, stress‐strain cycles were recorded until the alloy had completely stabilised. These cycles were then used to identify material parameters of non‐linear kinematic and isotropic models. The focus was on plasticity models (Armstrong‐Frederick, Chaboche, Voce) that are usually implemented in commercial finite element codes. Simulated cyclic responses with the identified material models were compared with experiments and showed a good agreement. The identified material parameters for the CuAg alloy under investigation can be used directly in finite element models for cyclic plasticity simulations, thus enabling a durability analysis of components under thermo‐mechanical loads to be performed, particularly in the field of steel‐making plants.     

Loading–unloading curves of interlocking grouted stabilised sand-flyash brick masonry

Loading–unloading and reloading stress–strain curves of interlocking grouted stabilised sand-flyash brick masonry under uniaxial cyclic compressive loading are presented. Five cases of loading at 0°, 22.5°, 45°, 67.5° and 90° to the bed joints are considered. The brick units and masonry system developed by Prof. S.N. Sinha is used in present investigation. A mathematical model to describe the Loading–unloading–reloading response of this masonry system is proposed. The model accounts for the effect of residual strain on the cyclic compressive behaviour. The model uses simple polynomial functions. The loading and unloading curves are transformed to a normalised co-ordination system on which all the curves plot within a narrow range. A parent polynomial is developed to fit the curve on this coordinate system. Then individual reloading and unloading curve are obtained by transferring the parent equation to the stress–strain coordinate system. The present model for Loading–unloading and reloading curves compare well with the experimental data for five cases of loading under consideration.     

Nichtmagnetisierbarer warmbeständiger nichtrostender Stahl für Wälzlager

Nonmagnetic heating‐resistant stainless steel for roller bearings A low cost austenitic chromium manganese steel with about 1 mass% of carbon and nitrogen was molten under normal pressure which reveals an amazing combination of properties. Starting from a yield strength of about 600 MPa it is cold work hardened to 60 HRC. This high hardness is brought about for the first time without a martensitic microstructure which is usual for roller bearings. In addition this steel is stainless, non‐magnetic and heating resistant up to about 500 °C, i.e. a material to serve under complex loading. Manufacturing by ingot metallurgy, ESR, hot working, solution annealing and machining was carried out on an industrial scale. The investigation of the structure was carried out on several scales, beginning with the electronic structure, the TEM structure, the light optical microscopy up to macro‐etchings. In this manner an extensive understanding of the outstanding combination of properties of the steel named CARNIT was derived.     

Stress‐life prediction of 25°C polypropylene materials based on calibration of Zhurkov fatigue life model

In this study, to evaluate the chemical and mechanical properties of polypropylene (PP), activation‐energy and tensile tests were performed at room temperature (25°C) on pure PP and PP reinforced with glass fibre (GF). To improve the prediction accuracy of the fatigue life, three models based on the calibration of the Zhurkov model were proposed: a regression model, modified strain‐rate model and lethargy coefficient‐based model. Based on the experimental data analysis and statistical assessment results, we proposed a modified strain‐rate model that satisfies the dependency of the physical parameters and is congruent with the predicted fatigue life data. The experimental data and modified strain‐rate model were compared with the direct cyclic analysis results. The tendency of the frequency factor as a correction parameter in the modified strain‐rate model corresponded to the experimental activation energy and the increasing GF content.     

Texture effect on serrated flow in 2090 Al‐Li alloy

Tensile specimens of 1×6×25 mm in gauge dimension were cut from the surface and centre of 12.7 mm thick 2090 Al‐Li alloy plate, which were solution treated at 550 °C for 30 min, peak‐aged at 190 °C for 18 h, or reversion‐treated at 275 °C for 2 min. The flow stress of the centre layer was higher than that of the surface layer, regardless of the heat treatments. The textures of the surface and centre layers were approximated by the {001}<110> and {011}<211> orientations, respectively. The solution‐treated specimens gave rise to extensive serrations in their flow curves at a strain rate of 2×10^‐4 s^‐1. The serration amplitude was drastically reduced after the specimens were peak‐aged or reversion‐treated. However, for the peak‐aged alloy, the surface‐layer specimens underwent complex, serrated flows, whereas the flow curve of the centre‐layer specimen was almost devoid of serration. The serration, especially fine‐type serration in the peak‐aged and reversion‐treated specimens tended to disappear with increasing strain rate. The tensile behavior was explained in terms of the texture and strain rate.     

Cyclic behaviour of 12% Cr ferritic‐martensitic steel upon long‐term on‐site service in power plants

The strain‐controlled and stress‐controlled low‐cycle fatigue behaviour of served 12% Cr ferritic–martensitic steel is conducted at room temperature. Continuous softening is observed at both control modes, and the fitting results show that the fatigue properties of 12% Cr steel are not reduced significantly after 230 000 h service at 550 °C/13.7 MPa. Scanning electron microscopy has been employed to investigate the microstructure evolution after long‐term service. It is proved that the decomposition of martensite laths structure and the coarsening of carbides at grain/lath boundaries are the main reasons why the pipe bursts after 180 000 h service at 550 °C/17.1 MPa. The fracture under both control modes has been observed by using scanning electron microscopy, and it indicates coarse carbides along grain/lath boundaries are favourable sites for micro‐crack nucleation and the secondary cracks along the fatigue striations are formed by the connection of micro‐cracks nucleated during fatigue behaviour.     

Intermetallische Oxidationsschutzschichten für Titanlegierungen

Intermetallic Oxidation-Resistant Coatings for Titanium Alloys Intermetallic Ti-Al coatings were deposited onto near-a titanium alloy TIMETAL 1100 using magnetron sputtering. Two coating systems were investigated: gradient layers with increasing A1 con- tent towards the surface of the coatings and a multilayer system consisting of three single layers ofTi₃Al, TiAl and TiAl₃. The over- all coating thickness was 4 μm and 16 μm for both systems. Isother- mal oxidation tests at 750 °C revealed good oxidation resistance and effective oxygen prevention from the substrate by the coatings. Room temperature tensile tests after long-term exposure to air 600°C proved the beneficial influence of the coatings on the ductility of the base material. The coatings are highly ductile under creep conditions thus keeping oxygen away from the substrate alloy even at high straining. In some cases creep lifetime was consider- ably prolonged. No detrimental influence of the Ti-A1 coatings on the fatigue properties of TIMETAL I100 was found for the 4pm multilayer coatings, whereas fatigue limit under repeated strain was slightly decreased for the 16μm coatings.     

Temperature‐dependent uniaxial ratchetting of ultra‐high molecular weight polyethylene

Uniaxial stress‐controlled cyclic tests were performed on the ultra‐high molecular weight polyethylene (UHMWPE) polymer at different temperatures. The effects of stress level, stress rate, peak/valley stress hold and loading history on the ratchetting of the UHMWPE were discussed at different temperatures, and the temperature‐dependence of ratchetting was addressed. It is concluded from the experimental observations that the ratchetting of the UHMWPE depends greatly on the test temperature, and the ratchetting strain increases with the increasing temperature from ?20 to 37 °C, but decreases when the temperature is equal to or higher than 60 °C in some cases. The ratchetting is also time‐dependent and increases with the increase of peak stress hold time and the decrease of stress rate. The ratchetting presents apparent loading history dependence, and previous cyclic history with higher stress level remarkably restrains the occurrence of ratchetting in the subsequent cyclic loading cases with lower stress levels, but previous cyclic history with lower stress level hardly influences the ratchetting in the subsequent cyclic loading cases with higher stress levels.     

Elevated temperature low cycle fatigue of grey cast iron used for automotive brake discs

This paper evaluates the fatigue life properties of low carbon grey cast iron (EN-GJL-250), which is widely used for automotive brake discs. Although several authors have examined mechanical and fatigue properties at room temperatures, there has been a lack of such data regarding brake discs operating temperatures. The tension, compression and low cycle fatigue properties were examined at room temperature (RT) and at brake discs’ working temperatures: 500 °C, 600 °C and 700 °C. The microstructure of the material was documented and analysed. Tensile stress–strain curves, cyclic hardening/softening curves, stress–strain hysteresis loops, and fatigue life curves were obtained for all the above-mentioned temperatures. It was concluded, that Young’s modulus is comparable with both tension and compression, but yield its strength and ultimate strength are approximately twice as great in compression than in tension. All the mechanical properties remained quite stable until 500 °C, where at 700 °C all deteriorated drastically. During fatigue testing, the samples endured at 500 °C on average at around 50% of cycles at room temperature. Similar to other materials’ properties, the cycles to failure have dropped significantly at 700 °C.     

Strengthening of AISI 2205 duplex stainless steel by strain ageing

In this study, static strain ageing behavior of commercially available and solution heat treated duplex stainless steel was investigated and the effect of static strain ageing on the mechanical properties was also determined in detail. Some of as-received duplex stainless steel test specimens were pre-strained in tension by 5% and then aged at 100 °C, 200 °C, 300 °C, 400 °C, 500 °C and 600 °C for 30 min in furnace. Some of duplex stainless steel test specimens were solution heat treated at 1050 °C for 30 min, water quenched and then pre-strained for 5% in tension shortly after the solution heat treatment.In order to identify the effect of static strain ageing on the mechanical properties, the tensile strength, the change in the strength due to ageing (ΔY), elongation fracture and hardness were determined. The test results showed that the mechanical properties were affected by static strain ageing mechanism which was applied at different temperatures for same time interval.