Shear failure characterization of time–temperature sensitive interfaces

Poor interlayer bonding can lead to early failures and thus to a reduction in service life of bituminous pavements. For this reason, it is important to identify the parameters influencing the interlayer shear failure and to characterize their effect by means of laboratory test. In particular, this study is focussed on the effects of test temperature and deformation rate on the interlayer shear strength (ISS) of double-layered asphalt concrete specimens. First, the ISS was measured at temperatures ranging from 0 °C to 30 °C and deformation rates ranging from 0.5 mm/min to 9 mm/min using the Ancona Shear Testing Research and Analysis (ASTRA) device. Then the experimental data were analyzed using a two-stage statistical modelling approach. In the first stage, the variation of ISS versus deformation rate, at each testing temperature, was modelled using both a power-law and a logarithmic function. In the investigated range of deformation rate, the models allowed to estimate the mean ISS with residual standard error varying from 0.062 MPa to 0.128 MPa. Moreover, the linear regression coefficients, which measure the influence of the deformation rate on ISS, changed with temperature. In the second stage, both temperature and deformation rate were used as joint predictors of ISS by using an approach based on the superposition of their effects. Results showed that the time–temperature superposition approach is applicable and a sigmoid-shaped master curve for ISS was obtained. The proposed approach was validated by using ISS measurements obtained on the same materials with different test devices.     

Study of failure of EB-PVD thermal barrier coating upon near-α titanium alloy

The cracking failure of a conventional thermal barrier coating (TBC), consisting of a near-α titanium substrate, a NiCoCrAlY bond coat (BC), and a 8 wt.% yttria-stabilized zirconia ceramic layer deposited by electron beam-physical vapor deposition (EB-PVD) method, was studied by cyclic furnace testing and isothermal exposure. The scanning electron microscope, electron probe microanalysis, and microhardness indentation were used to probe the failure mechanism. It is found that due to the mismatch of the coefficient of thermal expansion, the as-deposited BC is suffered the long-term tensile creeping at room temperature. During the high-temperature exposure, the TBC locally rumples, bringing in-plane tensile stress at the shoulders, and out-of-plane tensile stress at the peak of the rumpled BC, where primal cracks are originated. During the cooling period, the ridges of substrate pulled by the local rumpling of the BC blocks the contracting of the BC, originating new cracks in planar BC, and aggravating the original cracks. Furthermore, the oxidation products pushed into the BC and the 8YSZ enlarges the TBC and cracks the substrate along the weakest diffused grain boundaries. The cracking failure related to the diffusion of the BC to the substrate is also discussed.     

The origin of the “crack tip” mode of failure in boron filaments

A study has been made of the crack tip mode of failure in boron filaments. Filaments produced by a technique that ensures a high percentage of this type of flaw were subjected to tensile testing and fracture characterization. These filaments were split longitudinally and etched to expose possible fracture-causing defects. A high density of voids was detected within the bulk boron coinciding with the residual stress neutral axis, which is also the location of the tip of the radial crack in the filament. A model is proposed for this type of failure that is consistent with experimental observations and theoretical predictions.     

Traction–separation laws for progressive failure of bonded scarf repair of composite panel

Repair of composites has become of considerable importance recently as modern commercial airliners employ much more composites in their airframes then previously. Major maintenance, repair, and overhaul (MRO) centers must contend with issues of damage tolerance, efficiency, integrity and cost of repairs. Computational methods have been developed to sufficiently sophisticated levels to aid in the design, evaluation and optimization of proposed repair schemes before they are implemented, potentially saving time and cost. In this paper, parametric studies on progressive failure analysis of a bonded scarf repair of a composite panel was performed. The study finds that finite element models with an appropriate material property degradation scheme using the micromechanics of failure criterion are able to predict the failure load of undamaged and damaged specimen. Results of the parametric studies on adhesive properties suggest that the failure stress of a repaired composite panel is more sensitive to the strength of the cohesive elements than to its toughness when a linear or trapezoidal softening traction–separation law is used, but the influence of adhesive strength is not significant when exponential softening traction–separation law is used.     

Multiscale aggregating discontinuities method for micro–macro failure of composites

The application of a multiscale method, called the multiscale aggregating discontinuities (MAD) method, to the failure analysis of composites is described. Two distinct features of the MAD method are the use of perforated unit cells, and the extraction of coarse-grained failure information. In the perforated unit cell, all subdomains of the unit cell that are not strictly elliptic are excluded, which enables the decomposition of its stable and unstable material. By means of these concepts, it is possible to compute an equivalent discontinuity at the macroscale, including both the direction and the magnitude of the discontinuity. This equivalent discontinuity is then passed to the macroscale along with the computed stress from the unit cell. The macroscale discontinuity is injected into the macro model by the extended finite element method (XFEM) procedure. In this paper, the method is improved by adding hourglass modes to the unit cell deformations, which better model growing cracks. Several examples comparing the MAD method with direct numerical simulations are presented.     

Tearing failure of web–flange junctions in pultruded GRP profiles

Details are presented in the preparation of T-section specimens for determining the tensile tearing strengths of web–flange junctions of two sizes of pultruded glass reinforced plastic GRP wide flange (WF) profiles. Two simple test rigs, used to carry out the tension tests on the web–flange junctions, are described. The tensile tearing strengths derived from 43 tests are presented and the characteristic failure mode of the web–flange junction is explained. It is shown that the tearing strengths of the junctions of the smaller WF profile are larger than those of the larger WF profile and, moreover, that they are only about one-quarter to one-third of the minimum transverse tensile strength of the material given the manufacturer's design manual.     

Numeral modeling of fracture failure of recycled aggregate concrete beams under high loading rates

Fracture tests of recycled aggregate concrete (RAC) beams of different sizes were conducted under high loading rates. In order to characterize the effect of high loading rate on the behavior of RAC beams, two new material models were used together with the commercial finite element software \(\hbox {ABAQUS}^{\mathrm{R}}\). One model is a viscoelastic model that can predict the increase of stiffness (modulus of elasticity) of RAC with increasing loading rate, and the other model is a multiphase composite model that can determine the effective stiffness of RAC taking into account the special internal structure of recycled aggregate. Two different cases were considered in the numerical simulation. Case 1 is for fixed beam size under different loading rates, and Case 2 is for fixed loading rate with different beam sizes. For Case 1, the simulation results of the maximum loads under three different strain rates agreed with test data quite well. The Force-CMOD curves of the numerical simulation and test data showed similar trends. The higher the strain rates, the wider the high stresses spread in the crack propagation zone. The good agreements with the test data indicated that the two new material models can characterize the effect of high loading rate on RAC beams very well. For Case 2, three beam sizes and one loading rate was studied. The post-peak Force versus CMOD curves from the simulation follow the same trend of the test data. The stress distributions in the beams of different sizes are similar. On the other hand, the maximum loads predicted by the numerical model did not agree very well with test data. This is due to the fact that the maximum forces of RAC notched beams exhibited size effect, which was not considered in the fracture criteria adopted in \(\hbox {ABAQUS}^{\mathrm{R}}\) and not in the two new material models. This will be a topic for future research.     

Multi-axial fatigue failure of orthopedic bone cement – experiments with tubular specimens

Bone cement is subjected to multi-axial cyclic loading when used to fixate orthopedic prostheses for joint arthroplasty. In this study, tubular specimens of poly(methylmethacrylate) (PMMA) bone cement are subjected to internal pressure and cyclic axial loading to ascertain the influence of multi-axial loading on fatigue life. As expected, it was found that the probability of survival of specimens under multi-axial loading was very much reduced relative to specimens loaded uniaxially. Furthermore, the variability of the fatigue life was increased by multi-axial loading. In conclusion, the results point to the importance of characterizing the behavior of bone cements under the multi-axial fatigue experienced in vivo, and of the importance of accounting for the multi-axial stress state when predicting implant longevity.     

Proof testing of ceramic materials—an analytical basis for failure prediction

An analysis is presented which permits the accurate prediction of component lifetimes after proof testing. The analysis applies to crack propagation controlled fracture but can be used as a conservative prediction when crack initiation is predominant. The analytical predictions are confirmed in a series of time-to-failure measurements.

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Zusammenfassung Man berichtet von einer Analyse die die genaue Voraussagung der Lebensdauer eines Keramikbestandteiles. nach den Abnahmeversuchen, ermöglicht. Die Analyse wird auf den durch Rißausdehnung kontrolierten Bruch angewandt, kann aber auch als eine konservative Voraussagung benützt werden im Fall wo die Rißeinleitung ausschlaggebend ist.Die analytische Voraussagung wurde durch eine Reihe von Zeit bis zum Bruch Messungen bestätigt.

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Résumé On présente une analyse permettant de prédire avec précision la durée de vie d'un composant céramique après épreuve de réception. L'analyse a trait aux ruptures dont la propagation des fissures est contrôlée, mais est utilisable en tant que prédiction conservative, dans le cas où l'amorçage de la fissure est la phase prédominante.Les prédictions analytiques se voient confirmées par des séries de mesures de durée de vie à rupture.

     

Impact failure of beams using damage mechanics: Part II—Application

The analytical model developed in Part I (Int J Impact Eng 2002;27(8):837–61) using continuum damage mechanics is used in this paper to predict the displacement to failure of beams subjected to static or dynamic loads producing large plastic strains. The beams, which were made of a ductile, strain rate sensitive material, were loaded at different positions on the span, by two tup geometries travelling with initial impact velocities up to 15 m/s. A reasonable correlation is obtained between the theoretical predictions and the experimental results for the displacements to failure.     

Failure of planetary pinions in earth moving equipment—a failure analysis approach

A series of failures of planetary pinions occurred in the final drive epicyclic gearbox of large trucks used in underground mining. A metallurgical analysis indicated that failure had occurred by internal rupture of the gear. This was attributed to poor heat treatment procedures used in case hardening the gear. This had induced high residual stresses just below the case/core interface, leading to the internal rupture of the gear.     

Impact failure of beams using damage mechanics: Part I—Analytical model

A simple theoretical method, which is based on ductile damage mechanics and which retains strain rate effects, is presented for predicting the failure of beams made from a perfectly plastic material and subjected to impact loads. For this class of materials, the strains can be estimated by defining a hinge length. The definition adopted here leads to reasonable predictions for the plastic strains and the strain rate, as shown by comparing the results with numerical calculations and experimental data. The equivalent strain and the strain rate can be used in the damage model to predict the failure of beams, as shown in a companion paper (Alves, Jones, Int J Impact Eng 2002;27(8):863–90).     

Synergetic effects of photo-oxidation and biodegradation on failure behavior of polyester coating in tropical rain forest atmosphere

This work aimed to study the comprehensive effects of photo-oxidation and biodegradation on different failure stages of polyester coatings,which were exposed to the tropical rainforest atmosphere.The surface morphology,aging products,local aging characteristics and electrochemical behavior of the coatings were characterized with scanning electron microscope(SEM),fourier transform infrared spectroscopy(FTIR),electrochemical impedance spectroscopy(EIS)and high-resolution dispersive Raman microscope.The results showed that the surface of coatings became rougher and fungal hyphae distributed more densely on surface with the increasing of exposure time.From the aspect of polymer structure,the ultraviolet radiation destroyed the main chain of polyester through the photo-oxidation process,resulting in the breakage of aliphatic ester bonds and the formation of esters.Further,the metabolites of fungi can promote the hydrolysis of oligomers produced by the photo-oxidation.In a short,the photo-oxidation could facilitate the biodegradation of the coating.With the synergistic effect of UV photo-oxidation and fungal biodegradation,a rapid diffusion tunnel between the coating surface and the metal substrate was established at the pore defects of the coating,which finally accelerated the corrosion failure process of the coating.The main corrosion products includeα-Fe₂O₃,ZnO and Zn₅(OH)₆(CO₃)₂.     

Second phase structure effect to the failure of an Al–Si casting

An Al–Si casting (blower pump) failed during pressure test. The material of the casting was aluminum–silicon alloy (BS-LM 9), in solution treated and aged condition. During pressure test the casting failed around 130 bar, while it was designed to sustain a pressure of 160 bar.The failed body was examined with the help of stereo microscope, optical microscope and scanning electron microscope. Fracture started from a sharp edge of a race present at the interior of the body. A granular dull gray fracture surface was observed during unaided visual examination. Fractographic studies showed that the mode of the fracture was transgranular and the material failed in brittle mode. Optical microscopic examination showed a dendritic structure having a continuous network of the secondary phase. A sample taken from the fracture region unveiled the crack propagation along the secondary phase network. It was recommend to use modification process during melting practice to avoid the stress raisers.     

Mechanical property of magnesium alloy sheet with hardening deterioration at warm temperatures and its application for failure analysis: Part II – failure analysis

The mechanical properties of a thin AZ31B Mg alloy sheet (with the thickness of 0.5 mm) were characterized for its anisotropy, temperature-dependent hardening (including its deterioration) and strain rate sensitivity based on simple tension test data measured at 100 °C, 150 °C, 200 °C, 250 °C, respectively, in Part I. As for anisotropy, simple tension tests were performed along three (rolling, transverse and in-between) directions to calibrate the Hill1948 yield function. As for temperature-dependent hardening, hardening as well as its deterioration (or softening) behavior observed beyond the uniform elongation limit was numerically characterized based on the inverse calibration method, in which strain rate sensitivity was also considered. The mechanical properties were confirmed to properly predict failure by strain localization for all the simple tension tests involved in the characterization procedure. Ultimately, the mechanical properties characterized in Part I were applied in Part II to analyze the failure by strain localization in the cross-shaped cup drawing tests developed as the benchmark problem for the NUMISHEET2011 conference [1]. The results showed that the mechanical properties with hardening deterioration properly predicted failure, while hardening without deterioration (obtained following the common practice) did not, confirming the importance of including the hardening deterioration in tensile property characterization, especially to predict forming failure by strain localization.     

Fatigue resistance and failure mechanisms of plasma-sprayed CrC–NiCr cermet coatings in rolling contact

The rolling contact fatigue (RCF) resistance and failure mechanisms of plasma-sprayed CrC–NiCr cermet coatings were experimentally investigated. Fatigue tests were conducted at two different contact stresses. At a given contact stress, thirteen rolling contact tests were performed to obtain the statistical result. The Weibull distribution plots of fatigue life data of the coatings were obtained. At higher contact stress, the bimodal distribution of the fatigue life data of the coatings was observed in the Weibull plot. The fatigue life of the coating decreased with increasing the contact stress. The failure modes of coatings could be classified into two main categories, i.e., spalling and delamination.     

Investigation on corrosion failure of Cr–Mo P11 grade pipe in primary section of a superheated steam generation system

This paper presents failure analysis of corroded steam pipes (Cr–Mo, P11 grade) at ammonia production plant. The corrosion and deposition morphologies are characterized using scanning electron microscopy. In addition, elemental composition analysis of deposited corrosion products is carried out using energy dispersive X-ray. This study clearly indicates the sensitivity of P11 grade steel pipe to intensive oxygen corrosion in steam generation systems with improper implementation of deoxygenating processes. Furthermore, this pipe grade and oxide layer on its surface are susceptible to cracking at the presence of high-level thermal stresses.