Magnetic Barkhausen emission technique for detecting the overstressing during bending fatigue in case-carburised En36 steel

The effect of bending fatigue at different maximum stress levels on the magnetic Barkhausen emission (MBE) has been studied in case-carburised En36 steel specimens. The low frequency MBE profile has been measured after unloading the specimen at different number of fatigue cycles. It has been found that, beyond 1000 MPa, the MBE peak height decreases just after few thousand cycles and the percentage reduction in the MBE peak increases with maximum bending stress level. The reduction in MBE peak at lower stresses (<1400 MPa) is attributed mainly to the effect of residual stresses becoming more compressive below the surface due to the application prior tensile stress. At higher stresses (1500 MPa), the variation in the MBE peak also indicates the effect of cyclic hardening and softening with progressive fatigue cycles. The MBE profiles measured after monotonic loading and unloading with different maximum stress levels also show similar reduction in the MBE peak with increase in pre-stress level. However, at higher stresses (>1400 MPa), the cyclic loading shows larger reduction in the MBE peak than the monotonic loading. This is attributed to the effect of cyclic microplasticity induced enhancement of dislocation density in addition to the residual stress modification. This study clearly shows the MBE technique can be used to detect the maximum stress level seen by the specimen beyond 1000 MPa. Any overstressing of this case-carburised steel beyond the fatigue limit of 1150 MPa can be easily detected from the percentage reduction in the MBE peak. Since the crack propagation stage is insignificant in these hard steels, the detection of any overstressing using the MBE technique would be very useful in assessing and preventing the impending catastrophic failure.     

Low Cycle Fatigue Evaluation of NiTi SESMA Thin Wires

This paper presents experimental studies on low cycle fatigue (LCF) life of super-elastic shape memory alloy (SESMA) wires. The effect of frequency of the loading and amplitude of the strain on the fatigue life has been studied individually. Various loading frequencies have been considered to study the effect of frequency, by keeping the amplitude constant. From the experimental data, it was found that the LCF life of the SESMA reduces with increase in the frequency. The effect of amplitude on the LCF life of SESMA has also been studied, and it was found that the SESMA cycled at lower net strain has more fatigue life than the one cycled at higher net strain. Further, the plastic strain accumulation is also more in the samples tested at the higher net strain loadings. The modulus of austenite is found to be by and large independent of the frequency and amplitude of the loading. Further, martensitic unloading modulus is same for all the minimum strain amplitudes.     

Effect of crystallographic orientation and grain boundary character on fatigue cracking behaviors of coaxial copper bicrystals

Four coaxial copper bicrystals were employed to study the slip morphologies and fatigue cracking behaviors during cyclic deformation. Three of them had high-angle grain boundaries (GBs) with nearly the same misorientation and one bicrystal had a twin boundary (TB). Different slip bands (SBs) operated near the GBs and TB, generating different dislocation arrangements, which are mainly determined by the crystallographic orientations of the component grains. The GBs suffered impingement or shear damage caused by slip difference from both sides. It is suggested that there is an energy increase in the interfaces between matrix and persistent slip bands (PSBs), GBs and TBs per cycle during cyclic deformation due to the accumulation of lattice defects, which would make the interface unstable. After a certain number of cycles, fatigue cracks initiated firstly at GBs for some bicrystals while fatigue cracking occurred preferentially at PSBs for the others. It is confirmed that the energy growth rate is an increasing function of the shear stress, strain amplitude and strain incompatibility, which results from slip differences on both sides of the interfaces. Interfaces with different energies and strain incompatibilities have different fatigue cracking resistance. It is found that GBs with defective and complex structure, and hence high interfacial energy accompanied by high modulus of the residual GB dislocation (GBD), are preferential sites for fatigue cracking, while the fatigue cracking appeared predominantly at PSBs when the modulus of the residual GBD is lower than that of a perfect dislocation with simple GB structure and low interfacial energy. The present model for the energy can predict well which kind of interface would form cracks preferentially during cyclic deformation in one coaxial bicrystal and which GB would need more cycles to initiate fatigue cracking between coaxial bicrystals with different GB characters.     

Microstructure and properties that change during hard cyclic visco-plastic deformation of bulk high purity niobium

The effect of strain amplitude and strain rate on the microstructure and the properties that change during hard cyclic visco-plastic deformation of bulk niobium of high purity at room temperature are systematically measured. These changes in the refractory metal niobium were studied at different tension-compression strain amplitudes (up to Ɛ = ±2%) and strain rates (up to έ (t) = 0.4 s⁻¹) during hard cyclic visco-plastic deformation in dependence on von Mises strain (up to Ɛ_vM = 13.8) during the equal channel angular pressing, respectively. The pure Nb was specified with respect to microstructure, micromechanical properties, density, gas content, tensile strength, Young's modulus, viability and fracture mechanics at fatigue failure for use in industry. The micro hardness and the indentation modulus of the nanostructured shear bands were significantly higher, but the plasticity was lower than that of the body metal between the shear bands. The decreasing Young's modulus (when increasing the strain rate) is related to the fatigue failure of the niobium during the tension-compression cycling and shows nucleation and thickening of the shear bands, as well as the changes in grain boundaries in the pre-fracture state.     

Nitinol Fatigue Life for Variable Strain Amplitude Fatigue

Nitinol fatigue testing results are presented for variable strain amplitude cycling. The results indicate that cycles smaller than the constant amplitude fatigue limit may contribute to significant fatigue damage when they occur in a repeating sequence of large and small amplitude cycles. The testing utilized two specimen types: stent-like diamond specimens and Z-shaped wire specimens. The diamond specimens were made from nitinol tubing with stent-like manufacturing processes and the Z-shaped wire specimens were made from heat set nitinol wire. The study explored the hypothesis that duty cycling can have an effect on nitinol fatigue life. Stent-like structures were subjected to different in vivo loadings in order to create more complex strain amplitudes. The main focus in this study was to determine whether a combination of small and large amplitudes causes additional damage that alters the fatigue life of a component.     

Neutron Diffraction Study of Low-Cycle Fatigue Behavior in an Austenitic–Ferritic Stainless Steel

By performing in situ neutron diffraction experiments on an austenitic–ferritic stainless steel subjected to lowcycle fatigue loading, the deformation heterogeneity of the material at microscopic level has been revealed. Based on the in situ neutron diffraction data collected from a single specimen together with the mechanical properties learned from the ex situ micro-hardness, a correlation has been found. The performance versus diffraction-profile correlation agrees with the cyclic-deformation-induced dislocation evolution characterized by ex situ TEM observation. Moreover, based on the refined neutron diffraction-profile data, evident strain anisotropy is found in the austenite. The high anisotropy in this phase is induced by the increase in dislocation density and hence contributes to the hardening of the steel at the first 10 cycles.Beyond 10 fatigue cycles, the annihilation and the rearrangement of the dislocations in both austenitic and ferritic phases softens the plastically deformed specimen. The study suggests that the evolution of strain anisotropy among the differently oriented grains and micro-strain induced by lattice distortion in the respective phases mostly affect the cyclic-deformationinduced mechanical behavior of the steel at different stages of fatigue cycles. The stress discrepancy between phases is not the dominant mechanism for the deformation of the steel.     

Potentialabhängigkeit der Schwingungsrißkorrosion von höherfestem Dalbenstahl in Salzwässern

Potential dependence of the corrosion fatigue of high strength sheet piling steel in salt water Cathodic protection of high strength steel, grade X 65, against corrosion fatigue (25 Hz) is not effective in seawater. An influence of hydrogen is assumed because hydrogen embrittlement occurs at slow strain-rates (not a constant load) under the condition of cathodic hydrogen evolution. The potential dependency of corrosion fatigue at 5 Hz was investigated with notched and smooth electropolished tensile specimens. The notched specimens showed a slight decrease of the number of cycles to failure with decreasing potential. The polished smooth specimens displayed cathodic protection. The results of the investigation can be explained by recent publications as an participation of hydrogen embrittlement, which happens only at critical strain rates and is dependent on the amount of straining, the frequency and the surface of the specimen.     

45碳钢低周疲劳与应力循环棘轮失效的实验研究

对调质处理的45碳素结构钢进行了应变循环低周疲劳实验以及应力控制棘轮失效实验．对于前者进行了带平均应变和不带平均应变的实验，以研究平均应变对低周疲劳特性的影响；对于后者研究了平均应力和应力幅值对棘轮失效的影响．应变循环实验表明：平均应变对循环饱和行为以及低周疲劳循环失效圈数并没有明显的影响，但对材料的循环初期循环塑性行为有影响．棘轮失效实验结果表明：当应力幅值较大而平均应力较小时，材料的棘轮失效主要归于较大塑性应变幅值引起的低周疲劳破坏；当平均应力较大而应力幅值相对较小时，材料的棘轮失效主要归于较大的棘轮应变引起的材料韧性破坏，其失效准则可以用最大单调极限应变来表征．     

Statistical Analysis of High-Cycle Fatigue Behavior of Friction Stir Welded AA5083-H321

A review of the literature revealed that high-cycle fatigue data associated with friction stir-welded (FSW) joints of AA5083-H321 (a solid-solution-strengthened and strain-hardened/stabilized Al-Mg-Mn alloy) are characterized by a relatively large statistical scatter. This scatter is closely related to the intrinsic variability of the FSW process and to the stochastic nature of the workpiece material microstructure/properties as well as to the surface condition of the weld. Consequently, the use of statistical methods and tools in the analysis of FSW joints is highly critical. A three-step FSW-joint fatigue-strength/life statistical-analysis procedure is proposed in this study. Within the first step, the type of the most appropriate probability distribution function is identified. The parameters of the selected probability distribution function, along with their confidence limits, are computed in the second step. In the third step, a procedure is developed for assessment of the statistical significance of the effect of the FSW process parameters and fatigue specimen surface conditions. The procedure is then applied to a set of stress-amplitude versus number of cycles to failure experimental data in which the tool translational speed was varied over four levels, while the fatigue specimen surface condition was varied over two levels. The results obtained showed that a two-parameter weibull distribution function with its scale factor being dependent on the stress amplitude is the most appropriate choice for the probability distribution function. In addition, it is found that, while the tool translational speed has a first-order effect on the AA5083-H321 FSW-joint fatigue strength/life, the effect of the fatigue specimen surface condition is less pronounced.     

Design maps for failure of all-ceramic layer structures in concentrated cyclic loading

A study is made of the competition between failure modes in ceramic-based bilayer structures joined to polymer-based substrates, in simulation of dental crown-like structures with a functional but weak “veneer” layer bonded onto a strong “core” layer. Cyclic contact fatigue tests are conducted in water on model flat systems consisting of glass plates joined to glass, sapphire, alumina or zirconia support layers glued onto polycarbonate bases. Critical numbers of cycles to take each crack mode to failure are plotted as a function of peak contact load on failure maps showing regions in which each fracture mode dominates. In low-cycle conditions, radial and outer cone cracks are competitive in specimens with alumina cores, whereas outer cone cracks prevail in specimens with zirconia cores; in high-cycle conditions, inner cone cracks prevail in all cases. The roles of other factors, e.g. substrate modulus, layer thickness, indenter radius and residual stresses from specimen preparation, are briefly considered.     

The effects of multiple re-shot peening on fretting fatigue behavior of Al7075-T6

Fretting fatigue is a consequence of small oscillatory movement between two contacting parts. This type of damage may give rise to significant reduction in fatigue life of the components. The resistance of materials against fretting fatigue can be improved by surface treatment such as shot-peening. In this work, the effect of multiple re-shot peening on resistance of Al7075-T6 against fretting fatigue was investigated. After each re-shot peening, the specimen was subjected to 80% of the fatigue life corresponding to the cycles to failure of the specimen after re-shot peening. This process continued until the effect of any further re-shot peening became insignificant. The results showed almost a 100% enhancement in fatigue life for the first re-shot peening. The enhancement, however, reduced logarithmically for the next re-shot peenings such that for the 4th re-shot peening the increase of fatigue life fell below 2% which was negligible. On the whole, the fretting fatigue life increased by 600% after shot peening and 4 times re-shot peenings.     

工业纯锆的低周疲劳特性及寿命预估

通过轴向对称应变控制法对工业纯锆的低周疲劳性能进行研究，讨论了工业纯锆的循环应力-应变响应、软硬化特性、累积滞后规律、疲劳寿命以及塑性应变能的影响。结果表明：在总应变幅大于0.5%时工业纯锆均表现出循环硬化；工业纯锆疲劳寿命满足Basquin-Coffin-Manson经验关系式，其过渡寿命为1548周；利用塑性应变能对疲劳损伤进行了有效评估，总应变幅度越低，滞回曲线面积越小，即塑性应变能越低，疲劳寿命越长；疲劳断口呈现明显的疲劳辉纹特征，随总应变幅的增加疲劳辉纹的数量减小宽度增加。     

回火对2Cr13钢疲劳损伤的恢复作用

采用应变疲劳过程中对试样进行中途回火的方法,研究了回火对疲劳损伤的恢复作用。实验结果发现,中途回火可使疲劳寿命延长。应变量越大,回火的作用越显著;循环寿命分数增加,回火的作用减少。ＴＥＭ观察表明,中途回火使位错密度及位错排列发生变化,从而使疲劳损伤在不同程度上恢复。疲劳断口ＳＥＭ观察发现,中途回火后,应变疲劳断口上的韧性断裂特征比未回火试样明显,说明中途回火使疲劳断裂机制发生了变化     

应变速率对IC10合金1100℃低周疲劳性能的影响

研究了不同应变速率（1×10^-2s^-1,1×10^-3s^-1,1.6×10^-4s^-1）下IC10合金1100℃下的低周疲劳性能、弹性模量、屈服强度和循环应力响应行为。研究结果表明：随应变速率的增加,材料的弹性模量没有变化,而材料的屈服强度明显增大,材料的屈服强度与应变速率的对数符合线性关系;材料在3种应变速率下都表现为明显的循环软化,随着应变水平的降低,该材料的循环软化行为逐渐地变弱。应变速率对低周疲劳寿命的影响规律与应变水平的大小有关：当总应变范围大于1.2%时,应变速率为1.6×10^-4s^-1的低周疲劳寿命最长,应变速率为1×10^-3s^-1的疲劳寿命最短,而应变速率为1×10^-2s^-1的疲劳寿命界于二者之间;当总应变范围为0.8%时,随着应变速率的减小,疲劳寿命明显缩短。     

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通过常规疲劳试验和超声疲劳试验测试模具钢107周次疲劳性能和108超高周次疲劳性能,对模具钢超高周疲劳试样断口进行了分析。将两种不同频率下模具钢试样的疲劳性能进行对比探讨模具钢的频率效应,将20 k Hz频率下两种不同尺寸试样的疲劳性能进行对比探讨模具钢的尺寸效应。结果表明:20 k Hz和130 Hz下模具钢107周次的疲劳极限相差9%,不同尺寸的两种圆弧形试样108周次下的疲劳极限相差16%。     

A Comparative Study on the Mechanical Behavior of Porous Titanium and NiTi Produced by a Space Holder Technique

NiTi and Ti porous specimens with appropriate pore characteristics for biomedical applications are produced by space holder method. Porosities of the specimens linearly increase from 14 to 65 and 42 to 70% for the Ti and NiTi specimens, respectively, with the urea space holder. Mechanical properties such as stiffness, fracture strain, and strength of the porous NiTi and Ti are adjustable with pore characteristics. The apparent elasticity modulus of NiTi specimens decrease from 3.5 to 0.73 GPa as porosity increases. Since the initial linear part of the stress-strain curve consists of elastic behavior, formation of stress-induced martensite, deformation and/or detwinning of martensite variants, and plastic deformation, the unloading slope of stress-strain curves is a better approximation for the elasticity modulus of the NiTi porous specimens as it is proved by an isotropic cubic cell model. The unloading slope of the NiTi specimen with 61% porosity is 3.1 GPa, while the apparent elasticity or loading slope is 0.85 GPa. In comparison to Ti, the high, recoverable strain of NiTi improves capability of it as a good candidate for bone replacement. Moreover, in contrast to Ti specimens, hysteresis loops are clearly observed in the stress-strain curves of NiTi specimens.     

氮—碳共渗钢的应变疲劳研究

45碳钢氮—碳共渗表面强化后的应变疲劳试验结果表明:共渗处理与基体,在整个试验应变范围内,均为大应变幅下呈循环硬化,小应变幅下呈循环软化;但在一定应变幅下,其硬化和软化程度各不相同。另外,共渗处理疲劳寿命的降低是表面强化层造成整体材料的塑性损失的结果。同时对断口和内部位错组态进行了观察分析。     

Synergistic Effects of Temperature,Oxidation and Stress Level on Fatigue Damage Evolution and Lifetime Prediction of Cross-Ply SiC/CAS Ceramic-Matrix Composites Through Hysteresis-Based Parameters

The damage development and cyclic fatigue lifetime of cross-ply SiC/CAS ceramic-matrix composites have been investigated at different testing temperatures in air atmosphere. The relationships between the fatigue hysteresis-based damage parameters, i.e., fatigue hysteresis dissipated energy, fatigue hysteresis modulus and fatigue peak strain and the damage mechanisms of matrix multicracking, fiber/matrix interface debonding, interface sliding and fibers failure, have been established. With the increase in the cycle number, the evolution of the fatigue hysteresis modulus, fatigue peak strain and fatigue hysteresis dissipated energy depends upon the fatigue peak stress levels, interface and fibers oxidation and testing temperature. The fatigue life S-N curves of cross-ply SiC/CAS composite at room and elevated temperatures have been predicted, and the fatigue limit stresses at room temperature, 750 and 850 °C, are 50, 36 and 30% of the tensile strength, respectively.     

Study on Fatigue Properties of Turbine Disk Groove Modeling Specimens of GH4720 Alloy

基于航空发动机涡轮盘榫槽结构特点及其工作状态,采用榫槽模拟件对GH4720合金的疲劳失效机理和裂纹扩展寿命进行了实验研究和理论分析。研究结果表明:GH4720合金榫槽模拟件的疲劳失效表现为3个阶段:(i)模拟涡轮盘榫槽处由于较高的应力集中而产生滑移,进而萌生裂纹;(ii)随着应力集中和循环载荷的持续,相邻晶粒间位错开动、发生滑移,裂纹在晶粒间传递;(iii)随着应力强度因子范围增大,剪应力和主应力交互作用、滑移系开动及位错在不同滑移系间的运动,裂纹快速扩展。在实验基础上建立了GH4720合金的疲劳裂纹扩展寿命模型,基于有限元分析的榫槽处的应力和裂纹扩展寿命模型得到的裂纹扩展寿命与实验结果相符,表明该裂纹扩展寿命模型可用于工程中预测涡轮盘的剩余寿命。