Modellierung des Ermüdungsrisswachstums in Schweißverbindungen unter Berücksichtigung von Schweißeigenspannungen

The present paper contains research results determined within the framework of a project called IBESS (?Integrale Bruchmechanische Ermittlung der Schwingfestigkeit von Schweißverbindungen“) by the Materials Mechanics Group of the Technische Universität Darmstadt [1]. Aim is to calculate the fatigue life of welded joints by taking into account the effect of residual stresses and the influence of the weld toe geometry. Here, the fatigue life is regarded as period of short fatigue crack growth. Two and three dimensional finite element models, with cracks as initial defects, are constructed for this purpose. Fatigue crack growth analyses are performed by using the node release technique together with the finite element program ABAQUS. The welding residual stresses as well as the plasticity induced crack closure effects are considered. Structural calculations are performed in order to introduce residual stress fields in finite element models. The calculated compressive residual stress field matches the measured one especially in the weld notch area. The effective cyclic J‐integral (ΔJ_eff) is used as crack tip parameter in a relation similar to the Paris equation for the calculation of the fatigue life. For this purpose, a Python code was written for the determination of ΔJ_eff at every crack length phase. The calculated fatigue lives were compared with experimental data and a good accordance between both results was achieved. The impact of welding residual stresses on ΔJ_eff as well as on the fatigue life during short crack growth was investigated. As expected, results revealed that at lower stress amplitude, a compressive residual stress field is favorable to the fatigue life, whilst a tensile residual stress field is unfavorable. The influence of residual stresses can be neglected only for large load amplitudes.     

Schleifbearbeitung von Hart‐Weich‐Verbunden – Finite‐Elemente‐Simulation des Schleifprozesses von hybriden Schichtverbunden

Grinding of ceramic‐metal‐compounds – finite element analysis simulation of the grinding process of hybrid stratified compounds In this paper, the subproject TP 8 “Grinding of ceramic‐metal‐compounds” is been introduced. An adapted grinding strategy should be created for the production of a ceramic‐cemented carbide compound drill. This aim should be obtained with experimental analysis and the use of finite element analysis to simulate the grinding process of ceramic‐cemented carbide compound drill. Furthermore a basic approach for simulating the grinding process of hybrid stratified compounds is been presented, which should be a basis for a finite element analysis simulation of a grinding process of ceramic‐cemented carbide compound drill.     

Wechsellast‐Prüfung von Hüftgelenk‐Pfannen mit keramischen Einsätzen

Fatigue Test of Hip‐Joint Cups with Ceramic Inserts A safe design of hip‐joint components for the long‐term use in humans requires an evaluation of the fatigue lifetime under the in‐vivo loading conditions. For compound cups with ceramic inserts no standardized or commonly agreed procedure exists up to now. Therefore, a test is presented here which is practised by the authors and which possibly could be the basis for a standard. Because of the expensive testing procedure and the large number of possible cup‐insert combinations a failure test with only few samples was chosen.     

Vorhersagemodell für die Wachstumsraten kurzer Risse auf der Basis von Kmax‐konstant‐Versuchen an M(T)‐Proben

Prediction model for the growth rates of short cracks based on K_max‐constant tests with M(T) specimens The fatigue crack growth behaviour of short corner cracks in the Aluminium alloys Al 6013‐T6 and Al 2524‐T351 was investigated. The aim was to determine the crack growth rates of small corner cracks at stress ratios of R = 0.1, R = 0.7 and R = 0.8 and to develop a method to predict these crack growth rates from fatigue crack growth curves determined for long cracks. Corner cracks were introduced into short crack specimens, similar to M(T)‐specimens, at one side of a hole (Ø = 4.8 mm) by cyclic compression (R = 20). The pre‐cracks were smaller than 100 μm (notch + precrack). A completely new method was used to cut very small notches (10–50 μm) into the specimens with a Focussed Ion Beam. The results of the fatigue crack growth tests with short corner cracks were compared with long fatigue crack growth test data. The short cracks grew at ΔK‐values below the threshold for long cracks at the same stress ratio. They also grew faster than long cracks at the same ΔK‐values and the same stress ratios. A model was developed on the basis of K_max‐constant tests with long cracks that gives a good and conservative prediction of the short crack growth rates.     

Ausgewählte Ergebnisse der Untersuchung der Prozesse des Schmelzens und der Erstarrung beim Schmelzschweißen und Schmelzlöten mittels der materiellen Modellierung

In the article a method for the material modelling is described under application of visually transparent materials of the thermal and chemical solidification processes when welding and soldering. All solidification processes carried out independently of the form of the primary crystals, first about the planar one, then cellular and in the end dendritically growth the solidification structure. It is determined by the chemical composition of the weld and soldering good, the weld, soldering, crystallization or solidification speeds and by the temperature gradients at the solidification front particularly. The vacancy concentration is made by the temporary formation of so‐called zipper primary grain boundaries in the solidification structure when welding. Among other things a preferential growth direction of the primary crystals explains itself by the fast growth of so‐called victim crystals which completes the known theories of the preferential growth.     

A High‐Performance Self‐Regenerating Solar Evaporator for Continuous Water Desalination

Emerging solar desalination by interfacial evaporation shows great potential in response to global water scarcity because of its high solar‐to‐vapor efficiency, low environmental impact, and off‐grid capability. However, solute accumulation at the heating interface has severely impacted the performance and long‐term stability of current solar evaporation systems. Here, a self‐regenerating solar evaporator featuring excellent antifouling properties using a rationally designed artificial channel‐array in a natural wood substrate is reported. Upon solar evaporation, salt concentration gradients are formed between the millimeter‐sized drilled channels (with a low salt concentration) and the microsized natural wood channels (with a high salt concentration) due to their different hydraulic conductivities. The concentration gradients allow spontaneous interchannel salt exchange through the 1–2 µm pits, leading to the dilution of salt in the microsized wood channels. The drilled channels with high hydraulic conductivities thus function as salt‐rejection pathways, which can rapidly exchange the salt with the bulk solution, enabling the real‐time self‐regeneration of the evaporator. Compared to other salt‐rejection designs, the solar evaporator exhibits the highest efficiency (≈75%) in a highly concentrated salt solution (20 wt% NaCl) under 1 sun irradiation, as well as long‐term stability (over 100 h of continuous operation).     

Charakterisierung von Randentkohlungsvorgängen bei der Austenitisierung des Wälzlagerstahls 100Cr6. Teil 2: Modellierung des Kohlenstoff‐Tiefenverlaufs mit Hilfe der Methode der Finiten Elemente

Characterization of Decarburisation Processes During Austenitising of the Rolling Bearing Steel 100Cr6. Part 2: Modelling of the Carbon Concentration Profile by Means of the Finite Element Method The quantitative measurement of carbon concentration‐distance curves serves as fundamental prerequisite for the evaluation of rim zone properties connected with decarburisation processes in material science. This was shown in part 1 of the present work with two samples from through‐hardenable rolling bearing steel 100Cr6 (SAE 52100) austenitised in different oxidising atmospheres by position dependent determination of hardness, residual stresses, and X‐ray line broadening ({211} α’‐Fe diffraction line). In practice, it is important to predict carbon concentration‐distance curves under prevailing heat treatment conditions or to conclude conversely from profile measurements. Based on a refined kinetics model of a diffusion‐controlled process, part 2 therefore presents a simulation tool developed by means of the finite element method (FEM). Apart from the concentration dependence of the diffusion coefficient, it also considers the decarburisation induced austenite‐ferrite phase transformation, the time dependent influence of scaling, and variable atmosphere conditions. The interpretation of the carbon concentration‐distance curves, measured very accurately in the rim zone of both 100Cr6 samples by secondary ion mass spectrometry (SIMS), confirms the possibilities of application of the new numerical tool.     

Comparison of serum albumin,C‐reactive protein and carotid atherosclerosis as predictors of 10‐year mortality in hemodialysis patients

Serum albumin, C‐reactive protein (CRP), and the intima‐medial thickness of the common carotid artery (CA‐IMT) are associated with clinical outcomes in hemodialysis (HD) patients. However, it remains unclear which parameters are more reliable as predictors of long‐term mortality. We measured serum albumin, CRP, and CA‐IMT in 206 HD patients younger than 80 years old, and followed them for the next 10 years. One hundred sixty‐eight patients (age: 57 ± 11 years, time on HD: 11 ± 7 years) were enrolled in the analyses. We divided all patients into three tertiles according to their albumin levels, and conducted multivariate analyses to examine the impact on 10‐year mortality. Seventy‐three (43.5%) patients had expired during the follow‐up. Serum albumin was significantly lower in the expired patients than in the surviving patients (3.8 ± 0.3 vs. 4.0 ± 0.3, P<0.01), while CRP (4.7 ± 5.0 vs. 2.8 ± 3.5 g/L, P=0.01) and CA‐IMT (0.70 ± 0.15 vs. 0.59 ± 0.11 mm, P<0.01) were significantly higher in the expired group. The multivariate analysis revealed that there was a significantly higher risk for total mortality in HD patients with serum albumin <3.8 g/dL (odds ratio 5.04 [95% CI: 1.30–19.60], P=0.02) when compared with those with albumin >4.1 g/dL. In contrast, CRP and CA‐IMT did not associate with total death. It follows from these findings that serum albumin is more superior as a mortality predictor compared with CRP and CA‐IMT in HD patients.     

Mikrostrukturelle Veränderungen von Magnesium‐Druckgusslegierungen nach langzeitiger thermischer Beanspruchung

Microstructural Changes of Pressure Die Cast Magnesium Alloys after Long‐Term Thermic Loading The expansion of the application of pressure die cast magnesium alloys for automobiles requires the development of new alloys and the comprehensive assessment of available alloys on aggravated conditions, too. Such conditions are also given at higher temperatures, which can cause the creep of the material and lead to the component failure. Because the microstructural stability decisively depends on the thermic loading, this paper deals with the change of the microstructure and the hardness of the alloys AZ91, AM50 and AE42 after a long‐term annealing at 150 °C and 200 °C in comparison to the pressure die as‐cast condition. The results reveal clear differences of the microstructural stability of the alloys AZ91 and AM50 on the one hand and the alloy AE42 on the other hand. Due to the long‐term annealing at 150 °C the alloys AZ91 and AM50 show chiefly an intense precipitation of Mg₁₇Al₁₂ from the Al‐rich eutectic α‐phase. Furthermore at 200 °C, it is observed the coagulation and coarsening of these precipitates, too. The last appearances are connected with a weakening of the material. Regarding the alloy AE42, the changes of the precipitation state are not so intensely and do yet not lead to a microstructural weakening.     

Veränderungen der mechanischen Eigenschaften von Magnesium‐Druckgusslegierungen nach langzeitiger thermischer Beanspruchung

Changes of the Mechanical Properties of Pressure Die Cast Magnesium Alloys Subjected to Long‐Term Thermal Exposure The thermal resistance of pressure die cast magnesium alloys is yet not investigated sufficiently. In order to assess the effect of a thermal exposure on the microstructural stability and on the strength and deformation behaviour, the alloys AZ91, AM50 and AE42 are subjected to a long‐term annealing for 1000 h at 150 °C and 200 °C. After the annealing, tensile tests, in situ tensile tests and microhardness measurements are carried out and the results are discussed on the basis of the microstructural changes.     

Experimentelle und analytische Untersuchung des out‐of‐plane‐Verhaltens von unbewehrten Mauerwerkswänden unter Erdbebenbelastung

Experimental and analytical investigation of the seismic out‐of‐plane behavior of unreinforced masonry walls In addition to the vertical and horizontal load‐bearing in‐plane, masonry must also withstand out‐of‐plane loads that occur in earthquake scenarios. The out‐of‐plane behavior of unreinforced masonry walls depends on a variety of parameters and is very complex due to the strong non‐linearity. Current design methods in German codes and various international codes have not been explicitly developed for out‐of‐plane behavior and contain considerable conservatism. In the present work, shaking‐table experiments with heat‐insulating masonry walls have been conducted to investigate the out‐of‐plane behavior of vertical spanning unreinforced masonry walls. As shown in previous numerical investigations, important parameters are neglected in existing design and analysis models and the out‐of‐plane capacity is underestimated significantly. In the conducted experiments the results of these numerical investigations are verified. Furthermore, the development of an analytical design model to determine the force‐displacement relationship and the out‐of‐plane load‐bearing capacity considering all significant parameters is presented.     

Ermittlung von Verfahrensgrenzen für das Fügen durch Knickbauchen anhand des Werkstoffes E235+N

Through a systematic approach and the consistent comparison of the results between experimental and numerical investigations, a deep understanding of the bulging mechanisms has been first developed. From these investigations process limitations were derived and presented in the form of a working diagram for the material E235+N. With regard to a wide industrial use of upset bulging as a joining technology, a technologically, productively as well as economically appropriate method could be developed and validated by means of practical and numerical experiments.     

Engineering C*‐integral and COD estimates for nonidealized circumferential through‐wall cracked pipes at elevated temperature

In this study, creep fracture mechanics parameters, C^*‐integral and crack opening displacement (COD) rate, are estimated for a nonidealized circumferential through‐wall crack (TWC) in pipes. The GE/EPRI and enhanced reference stress (ERS) methods are employed. As for creep condition, the Norton and RCC‐MRx creep models are considered for secondary and primary‐secondary creep strain, respectively. The bending moment, axial tension, and internal pressure are applied to a pipe with a nonidealized circumferential TWC, as individual loads. Three‐dimensional elastic‐creep finite element (FE) analyses are performed, and the predictions from the GE/EPRI and ERS methods are compared with FE results. For the Norton creep model, both methods show good agreement with the FE results. For the RCC‐MRx creep model, only the ERS method can be used, and it provides accurate predictions comparing with FE results. Based on the comparison results, the use of the present engineering C^*‐integral and COD estimation methods for nonidealized circumferential TWC is validated.     

NixMnyCozO Nanowire/CNT Composite Microspheres with 3D Interconnected Conductive Network Structure via Spray‐Drying Method: A High‐Capacity and Long‐Cycle‐Life Anode Material for Lithium‐Ion Batteries

The combination of high‐capacity and long‐term cycling stability is an important factor for practical application of anode materials for lithium‐ion batteries. Herein, Ni_xMn_yCo_zO nanowire (x + y + z = 1)/carbon nanotube (CNT) composite microspheres with a 3D interconnected conductive network structure (3DICN‐NCS) are prepared via a spray‐drying method. The 3D interconnected conductive network structure can facilitate the penetration of electrolyte into the microspheres and provide excellent connectivity for rapid Li⁺ ion/electron transfer in the microspheres, thus greatly reducing the concentration polarization in the electrode. Additionally, the empty spaces among the nanowires in the network accommodate microsphere volume expansion associated with Li⁺ intercalation during the cycling process, which improves the cycling stability of the electrode. The CNTs distribute uniformly in the microspheres, which act as conductive frameworks to greatly improve the electrical conductivity of the microspheres. As expected, the prepared 3DICN‐NCS demonstrates excellent electrochemical performance, showing a high capacity of 1277 mAh g^?1 at 1 A g^?1 after 2000 cycles and 790 mAh g^?1 at 5 A g^?1 after 1000 cycles. This work demonstrates a universal method to construct a 3D interconnected conductive network structure for anode materials     

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.