The fatigue behavior and mechanism of FV520B-I with large surface roughness in a very high cycle regime

The fatigue properties of FV520B-I up to 10⁹ cycles when the surface roughness R_a ≈ 0.6 were tested and compared with two groups of previously obtained test results. The test results showed that the S-N curve continuously moved downward and the transition stress at which the crack origin changed from the surface to the subsurface decreased with an increase of surface roughness, and the conventional fatigue limit finally appeared. The initiation mechanism of subsurface cracks in a very high cycle fatigue regime was independent of surface roughness. The surface fatigue limit and the high cycle fatigue life were predicted by relevant models. The competition mechanism between surface cracking and subsurface cracking was further discussed.     

Evaluating surface deformation and near surface strain hardening resulting from shot peening a tempered martensitic steel and application to low cycle fatigue

The plastic deformation resulting from shot peening treatments applied to the ferritic heat resistant steel FV448 has been investigated. Two important effects have been quantified: surface roughness and strain hardening. 2D and 3D tactile and optical techniques for determining surface roughness amplitude parameters have been investigated; it was found that whilst R_a and S_a were consistent, S_z was generally higher than R_z due to the increased probability of finding the worst case surface feature. Three different methods for evaluating the plastic strain profile have been evaluated with a view to establishing the variation in yield strength near the surface of a shot peened component. Microhardness, X-ray diffraction (XRD) line broadening and electron backscatter diffraction (EBSD) local misorientation techniques were applied to both uniaxially deformed calibration samples of known plastic strain and samples shot peened at intensities varying from 4A to 18A to establish the variation in plastic strain and hence the variation in yield strength. The results from the three methods were compared; XRD and EBSD profiles were found to be the most similar with microhardness profiles extending much deeper into the sample. Changes in the measured plastic strain profile after exposure to low cycle fatigue and the correlation of these changes with the cyclic stress–strain behaviour of the material are also discussed with a view to assessing the importance of the dislocation profile in component life assessment procedures.     

Effect of abrasive water jet machining parameters on aramid fibre reinforced plastics composite

This paper presents a study on the effect of abrasive water jet machining (AWJM) process parameters on surface roughness (R _a) and kerf taper ratio (T _R) of aramid fibre reinforced plastics (AFRP) composite. Taguchi’s design of experiment was used as the experimental approach. Through analysis of variance (ANOVA), it was found that the traverse rate was considered to be the most significant factor in both R _a and T _R quality criteria. R _a and T _R were reduced as increasing the hydraulic pressure and reducing the standoff distance and traverse rate. However, there was no clear pattern for abrasive mass flow rate on both R _a and T _R. Therefore, it was confirmed that increasing the kinetic energy of water jet may produce a better quality of cuts. Mathematical models were also developed using multiple linear regression analysis to predict the performance of R _a and T _R in terms of AWJM process parameters. Considerably, the models are useful in predicting R _a and T _R in AWJM of AFRP laminate as shown in present study.     

Sidewall roughness characterization and comparison between silicon and SU-8 microcomponents

Surface characterization of microcomponents provides key information to help understand and predict the performance of microdevices. For example, in a microgear transmission, the surface roughness has a strong effect on the friction, running life and power consumption. In a static fluid microdevice, the liquid distribution is influenced by the surface tension and capillary force, which are primarily determined by the surface roughness. In a flowing microchannel case, surface roughness results in unsteady secondary flows. In this paper, a study is presented to characterize the surface roughness of silicon and SU-8 microcomponents. The silicon components studied are fabricated using an ICP plasma etching system manufactured by Surface Technology Systems. The sidewall roughness of the component is measured using atomic force microscopy. Repeated measurements have been conducted at different sidewall depths of the microstructure. The AFM images of the measurements are present. The measurement results show that the sidewall is smoother at the lower level than that at the upper level in a Si microstructure, and the average roughness R_a obtained throughout the depth is 151.11 nm. The UltraThick SU-8 Process (UTSP) provides another way to fabricate microstructures as thick as 1 mm with a very vertical sidewall. The roughness contour of the sidewall shows that the surface topography is similar throughout the depth. The average roughness R_a is 46.46 nm. Other surface parameters, such as R_q, R_p − p, R_pk and R_sk, are also obtained and analysed. The implication of the smooth surface roughness of SU-8 structures to their applications is discussed in terms of transmission efficiency, the changes in friction to flowing liquid in a microchannel and the changes in the surface tension and capillary effect.     

Potential fatigue strength improvement of AA 5083-H111 notched parts by wire brush hammering: Experimental analysis and numerical simulation

The effects of milling as machining process and a post-machining treatment by wire-brush hammering, on the near surface layer characteristics of AA 5083-H111 were investigated. Surface texture, work-hardening and residual stress profiles were determined by roughness measurement, scanning electron microscope (SEM) examinations, microhardness and X-ray diffraction (XRD) measurements. The effects of surface preparation on the fatigue strength were assessed by bending fatigue tests performed on notched samples for two loading stress ratios R_0.1 and R_0.5. It is found that the bending fatigue limit at R_0.1 and 10⁷ cycles is 20% increased, with respect to the machined surface, by wire-brush hammering. This improvement was discussed on the basis of the role of surface topography, stabilized residual stress and work-hardening on the fatigue-crack network nucleation and growth. The effects biaxial residual stress field and surface work-hardening were taken into account in the finite element model. A multi-axial fatigue criterion was proposed to predict the fatigue strength of aluminum alloy notched parts for both machined and treated states.     

Inhomogene Verformungserscheinungen bei Schwingbeanspruchung des Vergütungsstahls 42 CrMo 4

Inhomogeneous Deformation Processes During Cyclic Loading of Quenched and Tempered Steel SAE 4140 The cyclic deformation behavior of a normalized steel SAE 4140 in the loading range σ_a < R_eS is characterized by softening and hardening phenomena. Cyclic softening processes are combined with inhomogeneous plastic deformations and the propagation of a fatigue Lüdersband. The following hardening process occurs homogeneously. At stress amplitudes σ_a < R_p0.2 the quenched and tempered SAE 4140 worksoftens continuously until crack initiation. Plastic deformation processes are extremely inhomogeneous and are concentrated on small fatigue zones. The inhomogeneity increases with decreasing tempering temperatures und stress amplitudes.     

Effects of treatment with low molecular weight phenol formaldehyde resin on the surface characteristics of oil palm (Elaeis quineensis) stem veneer

Even though oil palm (Elaeis quineensis) stem (OPS) is highly potential as an alternative raw material in wood industry, it possesses some inferior characteristics. One of the critical weaknesses is a high degree of veneer surface roughness that resulted in high resin consumption during plywood manufacture. The objective of this study was to investigate effects of treatment with low molecular weight phenol formaldehyde (LMWPF) resin on the wettability and surface roughness of OPS veneer. OPS veneers were segregated into two categories namely outer and inner layer veneer, prior to soaking in LMWPF resin solution to obtain weight percent gain of 16–20%. The wettability of OPS veneers was assessed with contact angle measurement according to the sessile drop method. The veneer surface roughness was evaluated by determining the average roughness (R_a), mean peak-to-valley height (R_z), and maximum roughness (R_max) using a stylus profilometer in accordance with DIN standard 4768. The results show that the effect of LMWPF resin treatment on the surface roughness of the veneers is statistically significant. The technique used in the study was able to enhance the surface properties as well as improved the physical and mechanical properties of OPS plywood.     

Effect of stress relief groove on fretting fatigue strength and index for the selection of optimal groove shape

The applicability of small stress relief groove for the improvement of fretting fatigue strength was studied. Fretting fatigue tests were done using several kinds of grooved specimens. The shape of groove was systematically changed with parameters of groove radius R and tangential angle θ. The improvement of fatigue limit by a stress relief groove depended on both R and θ. The fretting fatigue limit with stress relief groove was increased with the increase of R and θ. The parameter θd (d: groove depth) was selected for the unified evaluation of the improvement. FEM stress analyses were done to investigate the stress condition. In a simple elastic FEM analysis assuming that the contact edge is ideally shaped, a highly compressive stress field was generated near the contact edge, where small cracks could never propagate. This suggested that such a simple analysis was not enough to solve this problem. Thus, an assumption to relieve the highly compressive contact pressure near the contact edge was introduced to explain the experimental fact that a crack could propagate. The profile change was simulated by the local plastic deformation at the contact edge calculated by elasto-plastic FEM deformation analysis. This deformation reduced the highly compressive contact pressure and enabled the crack propagation. As a result, it was found that fretting fatigue limit of grooved specimen could be evaluated on the basis of the maximum axial stress near the contact edge. The estimation of fretting fatigue limit using a relationship between K_t/K_t0 and θd provided a good estimation with the experimental results and it would be a useful method to select the optimal groove shape.     

Some considerations regarding finishing by abrasive flap wheels

The diminishing of the surface roughness of a metallic part can be performed by using various finishing methods, polishing by means of abrasive flap wheels being one of them. There are several factors that influence the roughness of surfaces finished by means of abrasive flap wheels. When polishing external cylindrical surfaces by means of abrasive flap wheels, the surface roughness can be changed more easily if the following elements are modified: the peripheral speed of the workpiece and of the abrasive flap wheel, the speed of the longitudinal feed, and the grit size of the abrasive material. Experimental research has allowed for the establishment of power-type functions which highlight the influence exerted by the above-mentioned factors on the size of the surface roughness parameters R _a , RS, RSm, Rku. Analyses of the experimental results have shown that, in the case of the R _a roughness parameter, from among the range of interactions of orders 2 and 3, only the interaction between the rotation speed of the abrasive flap wheel and the speed of the longitudinal feed seems to be significant.     

Quantifying the surface roughness effect in microindentation using a proportional specimen resistance model

The influence of the surface roughness on the indentation size effect in microindentation was examined using the proportional specimen resistance model. Stainless steel, aluminium, and copper surfaces were polished to different levels of roughness and subjected to microindentation. The results showed that the indentation size effect increases with increasing surface roughness, according to the proportional specimen resistance model. A normalized hardness equation H/H ₀ = (c ₀ + c ₁ R _a)/(a ₂ d) + 1 was established, and the value of c ₁ can be used to quantify the effect of surface roughness on the severity of the indentation size effect; this value was found to be highest for stainless steel, followed by copper and aluminium.     

Surface quality of thermally compressed Douglas fir veneer

The objective of this study is to evaluate surface quality of compressed Douglas fir (Pseudotsuga menziesii) veneer sheets in the form of its roughness. Veneer samples were compressed using pressure levels of 1.0 N/mm², 2.0 N/mm², and 2.5 N/mm² at two temperatures of 180 °C and 210 °C for 3 min. A fine stylus profilometer was used to evaluate surface roughness of the veneer samples. Three roughness parameters, namely average roughness (R_a), mean peak-to-valley height (R_z), and maximum roughness (R_max) values were determined. The results obtained in this study showed that the surface roughness parameters of the thermally compressed veneers decreased with increasing press temperature and pressure level. It appears that initial data found in this work would provide some benefit to more efficient use of adhesive to manufacture plywood and laminated veneer lumber (LVL) panels with enhanced properties.     

Fatigue assessment using an integrated threshold curve method - applications

This paper deals with the analysis and prediction of a high-cycle fatigue behaviour in notched and damaged specimens, as well as butt-welded joints by using a threshold curve for fatigue crack propagation that includes the short crack regime (a function of crack length, a). The approach regards the effective driving force applied to the crack as the difference between the total applied driving force defined by the applied stress distribution corresponding to a given geometrical and loading configuration, ΔK(a), and the threshold for crack propagation, ΔK_th(a). Chapetti’s model is used to estimate the threshold for crack propagation by using the plain fatigue limit, Δσ_eR, the threshold for long cracks, ΔK_thR, and the microstructural characteristic dimension (e.g. grain size). Applications, predictions and results, in good agreement with experimental results from the literature, demonstrate the ability of the method to carry out quantitative analyses of the high cycle fatigue propagation behavior (near threshold) of short cracks in different geometrical, mechanical and microstructural configurations.     

Effect of temperature on sliding wear of AISI 316 L(N) stainless steel – Analysis of measured wear and surface roughness of wear tracks

AISI type 316 L(N) austenitic stainless steel is major construction material in the prototype fast breeder reactor (PFBR) because of its good high temperature strength, toughness, creep and low cycle fatigue properties and compatibility with liquid sodium. Sliding wear experiments were carried out at various temperatures up to 550 °C at constant load (20 N) and sliding speed (0.8 m/s) using a pin-on-disc test rig as per the ASTM standard G99-05. Analysis of the test results presented that, the wear increased considerably with the temperature. For the characterization of worn surface topography, comprehensive profilometry study was performed using Talysurf CLI 1000 surface profilometer and R_a (arithmetic mean deviation) and S_a (arithmetic mean deviation of surface) parameters values were evaluated. The roughness parameters were correlated with the amount wear data obtained from the experiments at various testing temperatures. As the temperature increases during the sliding wear, the material loss is presented with more undulations resulting in higher surface roughness values.     

Effects of inclusion size and stress ratio on fatigue strength for high-strength steels with fish-eye mode failure

Experimental results indicate that the fatigue life reduces by about two orders of magnitude when inclusion size doubles. Then, a model is proposed for predicting the fatigue strength of high-strength steels with fish-eye mode failure based on the experimental results for the effect of inclusion size and stress ratio. In the model, the effect of inclusion size a₀ and stress ratio R on fatigue strength σ_a is expressed as σ_a ∝ a₀^m[(1 − R)/2]^α, where m and α are material parameters. The predicted results are in good agreement with our experimental results and the ones reported in literature.     

Influence of roughness parameters on coefficient of friction under lubricated conditions

Surface texture and thus roughness parameters influence coefficient of friction during sliding. In the present investigation, four kinds of surface textures with varying roughness were attained on the steel plate surfaces. The surface textures of the steel plates were characterized in terms of roughness parameter using optical profilometer. Then the pins made of various materials, such as Al-4Mg alloy, Al-8Mg alloy, Cu, Pb, Al, Mg, Zn and Sn were slid against the prepared steel plates using an inclined pin-on-plate sliding tester under lubricated conditions. It was observed that the surface roughness parameter, namely, R _a , for different textured surfaces was comparable to one another although they were prepared by different machining techniques. It was also observed that for a given kind of surface texture the coefficient of friction did not vary with R _a . However, the coefficient of friction changes considerably with surface textures for similar R _a values for all the materials investigated. Thus, attempts were made to study other surface roughness parameters of the steel plates and correlate them with coefficient of friction. It was observed that among the surface roughness parameters, the mean slope of the profile, Del a(Δ _a ), was found to explain the variations best.     

The effect of microstructure and environment on fatigue crack growth in 7049 aluminium alloy at negative stress ratios

The influence of environment and microstructure on fatigue crack growth has been investigated on a high strength 7049 aluminium alloy. This aluminium alloy was artificially aged to underaged (UA) and overaged (OA) microstructures. The heat treatment procedure was performed in order to obtain an UA and OA microstructure having the same yield strength properties, but differing in the mode of slip deformation: the UA alloy deforms by planar slip and that of the OA alloy by wavy slip. The crack growth measurements were performed in MT specimens at constant load ratios for R=0, −1, −2, −3 near-threshold and Paris regime in ambient air and vacuum conditions. Crack closure loads were measured in order to determine the P_open for each R ratio. Micromechanisms of near-threshold crack growth are briefly discussed for several concurrent processes involving environmentally assisted cracking with intrinsic microstructural effects. The results showed that the presence of humid air leads to a larger reduction in ΔK_th for both the ageing conditions, but the UA specimens were superior probably because of crack branching. The role of environmental effect and microstructures near-threshold regime seems to be more significant than any mechanical contributions to the crack closure, such as plasticity, roughness, oxide, etc.     

The surface topography of retrieved femoral heads

Excessive wear of UHMWPE sockets is considered detrimental to the long-term performance of total hip replacement procedures. Although many factors contribute to the wear process, laboratory experiments have indicated that one of the most important factors affecting the wear rate is surface topography and in particular, the arithmetic mean surface roughness, R _a, of the hard counterface. Surface roughness values were therefore obtained from the heads of 37 explanted and five new Charnley prostheses. The surface topography was measured using a Rodenstock RM 600 non-contacting profilometer. Five parameters were used to give a quantitative characterization of the surface texture; arithmetic mean surface roughness, R _a, root mean square (RMS) surface roughness, R _q, peak to valley height, R _t, average single peak to valley height from five adjoining sample lengths, R _z, and the skewness of the height distribution, Sk. Further, qualitative investigations were undertaken using a Joel-JSM-IC848 scanning electron microscope (SEM). The median values of R _a, R _q, R _t and R _z for explanted heads showed statistically significant increases when compared with values from new prostheses. No significant difference was found between any of these parameters measured in the anterior-posterior and the medial-lateral directions. This result may have important implications for the design of joint simulators. No correlation was found between any of the parameters and implant period.     

The influence of moisture content of raw material on the physical and mechanical properties,surface roughness,wettability, and formaldehyde emission of particleboard composite

The objectives of this research were to investigate surface characteristics, physical (thickness swelling) and mechanical (modulus of rupture, modulus of elasticity and internal bond strength) properties, and formaldehyde emission of particleboard composite, as affected by moisture content of wood. Three-layered particleboard panels manufactured from wood particles at five different moisture contents (20%, 40%, 60%, 80% and 95%). Roughness measurements, average roughness (R_a), mean peak-to-valley height (R_z), and maximum roughness (R_y), were taken from the sanded samples along and across the sandmarks using a fine stylus tracing technique. Contact angle measurements were obtained by using a goniometer connected with a digital camera and computer system. Statistical analysis showed significant differences in the surface roughness, contact angle, formaldehyde emission, physical and mechanical properties of the panels following moisture content. Based on the findings obtained from this study, an increase or decrease in the moisture content of wood beyond a certain limit, before chipping operations, negatively affected the wettability and smoothness of particles, and formaldehyde emission, physical and mechanical properties of particleboards.     

Effect of counterface roughness on adhesion of mushroom-shaped microstructure

In this study, the effect of the substrate roughness on adhesion of mushroom-shaped microstructure was experimentally investigated. To do so, 12 substrates having different isotropic roughness were prepared from the same material by replicating topography of different surfaces. The pull-off forces generated by mushroom-shaped microstructure in contact with the tested substrates were measured and compared with the pull-off forces generated by a smooth reference. It was found that classical roughness parameters, such as average roughness (R_a) and others, cannot be used to explain topography-related variation in pull-off force. This has led us to the development of an integrated roughness parameter capable of explaining results of pull-off measurements. Using this parameter, we have also found that there is a critical roughness, above which neither smooth nor microstructured surface could generate any attachment force, which may have important implications on design of both adhesive and anti-adhesive surfaces.     

Machining residual stresses

As part of an extended investigation into the effects of pre-and post-processing on shot peening residual stresses, residual stresses due to a controlled turning process were investigated in the aircraft alloy 817M40. Cylindrical specimens were produced on a centre lathe with all machine parameters fixed except for feedrate. A variation in the feedrate was used to produce different surface roughnesses varying from 1·2 to 6·6 μm R_a. The residual stress field resulting from the varying feedrate was established by the well known centre hole drilling method, albeit with a modification which assisted in determining the variation of residual stresses with depth. The results indicated a definite variation in axial residual stress distribution with surface roughness, with a rough surface showing higher tensile residual stresses. This variation was however not duplicated for hoop or circumferential stresses. Maximum tensile residual stress varied from 90 MN m^?2 in the 6·6 μm R_a surface to 50 MN m^?2 in the 1·2 μm R_a surface. Although residual stresses are generally ignored in design, either because of a lack of experimental results or for ease of application, the results indicate that some consideration must be given to machining residual stresses as these can enhance or reduce the fatigue life of engineering components. The study also indicates that turning operations associated with large plastic deformations are encountered during the machining process.

MST/3230