Inclusion-controlled high cycle fatigue behavior of a high V alloyed powder metallurgy cold-working tool steel

Axial loading fatigue tests were carried out to study the influence of inclusion on high cycle fatigue behavior of a high V alloyed powder metallurgy cold-working tool steel (AISI 11). The fatigue strength of 1538 MPa with endurance life of 10⁷ cycles were obtained by stair-case method. The fatigue specimens were also subjected to a constant maximum stress of 1650 MPa to investigate the relationship among inclusion origin size (10-30 μm), fish-eye size (70-130 μm) and fatigue life (10⁵-10⁷ cycles). The fatigue life was found to be dependent on the inclusion size and the crack propagating length. A compressive residual stress of 300-450 MPa turned out to be present at the specimen surface, and finally induced the interior failure mode. Further investigation into the correlation between stress intensity factors of inclusion origin and corresponding stages of fatigue crack growth and fatigue life revealed that the high cycle fatigue behavior was controlled by crack propagation. According to the fractographic investigation, two distinct zones were observed in fish-eye, representing Paris-Law and fast fatigue crack growth stage, respectively. Threshold stress intensity for crack propagation of 3.9 MPa√m was obtained from the well correlated line on the ΔK_I-log N_? graph. The fracture toughness can also be estimated by the mean value of stress intensity factor ranges for fish-eye.     

Effect of frequency and environment on fatigue behavior of a CVI SiC/SiC ceramic matrix composite at 1200 °C

The fatigue behavior of a SiC/SiC CMC (ceramic matrix composite) was investigated at 1200 °C in laboratory air and in steam environment. The composite consists of a SiC matrix reinforced with laminated woven Hi-Nicalon™ fibers. Fiber preforms had boron nitride fiber coating applied and were then densified with CVI SiC. Tensile stress-strain behavior and tensile properties were evaluated at 1200 °C. Tension-tension fatigue tests were conducted at frequencies of 0.1, 1.0, and 10 Hz for fatigue stresses ranging from 80 to 120 MPa in air and from 60 to 110 MPa in steam. Fatigue run-out was defined as 10⁵ cycles at the frequency of 0.1 Hz and as 2 × 10⁵ cycles at the frequencies of 1.0 and 10 Hz. Presence of steam significantly degraded the fatigue performance. In both test environments the fatigue limit and fatigue lifetime decreased with increasing frequency. Specimens that achieved run-out were subjected to tensile tests to failure to characterize the retained tensile properties. The material retained 100% of its tensile strength, yet modulus loss up to 22% was observed. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Acoustic emission and fracture behavior of GFRP woven laminates at cryogenic temperatures

This paper describes an experimental and analytical study on fracture and damage behavior of GFRP woven laminates at cryogenic temperatures. CT (compact tension) tests were carried out at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K) to evaluate the critical values of the fracture mechanics parameters. During the CT tests, AE (acoustic emission) method was implemented. AE signals can identify the critical load at which gross failure occurs. A FEA (finite element analysis) was also applied to calculate the fracture mechanics parameters. The failure criteria (Hoffman criterion and maximum strain criterion) or the damage variable based on the continuum damage mechanics was incorporated into the model to interpret the experimental measurements and to study the damage distributions within the specimen. Several methods of calculating J-integral are discussed.     

Effect of loading type on fatigue properties of high strength bearing steel in very high cycle regime

Very high cycle fatigue tests under axial loading at frequencies of 95 Hz and 20 kHz were performed to clarify the effect of loading type on fatigue properties of a high strength bearing steel in combination with experimental result of this steel under rotating bending. As a result, this steel represents the single P-S-N (probabilistic-stress-life) curve characteristics for surface-induced fracture and interior inclusion-induced fracture, just like that under rotating bending. However, fatigue strength is lower, where the run-out stress at 10⁹ cycles is evaluated to be 588 MPa, less than that under rotating bending with about 858 MPa. Occurrence probability of larger and deeper inclusion-induced fracture is much higher than that under rotating bending. Furthermore, the formation process of fine granular area (FGA) is independent of the type and frequency of loading, which is very slow and is explained as the crack nucleation process under the special dislocation mechanism. The stress intensity factor range at the front of FGA, ΔK_FGA, is approximately regarded as the threshold value controlling the stable propagation of interior crack. For the control volume of specimen under axial loading, the estimated value of fatigue limit by FGA is similar to experimental run-out stress value at 10⁹ cycles, but that by inclusion is larger. However, the corresponding estimated results under rotating bending are all conservative.     

Crack path in torsion loading in very high cycle fatigue regime

Torsion fatigue tests have been conducted at 20 kHz ultrasonic fatigue testing systems, and compared to the torsion fatigue data generated on 35 Hz conventional fatigue test machine to determine if there are any frequency effects, for steels including D38MSV5S steel and 100C6 steel. Results indicated that the S-N curves exhibit decrease in fatigue strength beyond 10⁷ cycles. The initiation in the Gigacycle regime is related to defects sometimes located beneath the surface which shows a competition between the maximum shear at the surface and the stress concentration under the surface, even in torsion.     

Transverse crack growth behavior considering free-edge effect in quasi-isotropic CFRP laminates under high-cycle fatigue loading

The high-cycle fatigue characteristics focused on the behavior of the transverse crack growth up to 10⁸ cycles were investigated using quasi-isotropic carbon fiber reinforced plastic (CFRP) laminates whose stacking sequence was [−45/0/45/90]_s. To assess the fatigue behavior in the high-cycle region, fatigue tests were conducted at a frequency of 100 Hz in addition to 5 Hz. In this study, to evaluate quantitative characteristics of the transverse crack growth in the high-cycle region, the energy release rate considering the free-edge effect was calculated. Transverse crack growth behavior was evaluated based on a modified Paris law approach. The results revealed that transverse crack growth was delayed under the test conditions of the applied stress level of σ_max/σ_b = 0.2.     

Influence of welding technique and temperature on fatigue properties of steel deposited with Co-based alloy hardfacing coating

This paper aimed to investigate the influence of welding technique and temperature on fatigue properties of heat-resistant steel with hardfacing coatings. The plasma transferred arc welding (PTAW) and the oxy-acetylene welding (OAW) were employed. The rotating bending fatigue tests were performed at room temperature (RT) and 500 °C. It was found the fatigue strength with 10⁷ cycles of OAW specimens at RT was lower than that of PTAW ones, possibly resulting from the higher amount of carbides in OAW coatings. The fatigue strength with 10⁷ cycles at 500 °C was higher than that at RT, which was mainly due to the interface delamination and the increase in ductility with increasing temperature. Two failure modes, i.e. the coating failure mode at RT and the coating-interface failure mode at 500 °C, were proposed. The fatigue life was predicted with the model considering the characteristic geometry of inclusions, the average hardness of coating, and the effect of external stress.     

Tension-tension fatigue behavior of GFRP woven laminates at low temperatures

This paper describes an experimental study on the fatigue damage behavior of GFRP woven laminates in terms of stiffness degradation and residual strength under cyclic loading at low temperatures. Uniaxial, load-controlled, tension-tension fatigue tests were conducted at room and low temperatures. The applied stress versus cycles to failure (S-N) relationships and fatigue limits were obtained for the GFRP woven laminates and the microcrack evolution due to fatigue loading was characterized using optical microscopy. Temperatures were also measured using a thermocouple embedded in the center of the specimens.     

Fatigue behaviour of tensile steel/CFRP joints

In this paper the fatigue performance of tensile steel/CFRP (Carbon Fibre Reinforced Polymer) double shear lap joints is discussed. Joints were realized with two steel plates and two CFRP strips bonded using epoxy adhesive. Fatigue tests were performed on 16 specimens under constant stress range loading cycles. Two stress ratios (R = 0.1 and R = 0.4) were considered to investigate their influence on the fatigue lifetime. Debonding was observed to occur at stress concentration zones and propagate along the CFRP/adhesive interfaces. The stiffness degradation of the steel joint due to progressive debonding of the adhesive represents an index for the subsequent and progressive global failure. S–N curves are defined and compared to the fatigue resistance of welded detail categories of the Eurocode 3. The tests showed that the stress ratio, R, has a marginal influence on the fatigue lifetime of the steel/CFRP double shear lap joints. Finally, a fatigue limit corresponding to a stress range in the steel plate equal to 75 MPa was conservatively estimated during the tests. The fatigue limit seems to be insensitive to the stress ratio R.     

Liquid helium cryostat for SQUID-based MRI receivers

We describe a liquid helium cryostat, developed to cool SQUID-based receivers in low field MRI systems. The cryostat has a 4 L liquid helium capacity, a hold time of over 3 days and accommodates 10 cm diameter receiver coils. New vacuum insulation methods reduce the noise level by at least an order of magnitude compared to existing commercial designs. The minimum detectable field at 425 kHz, with a 5 cm diameter circular coil, was estimated to be 0.018 fT/Hz^1/2 from Q-factor measurements and 0.035 fT/Hz^1/2 by direct measurement with a SQUID amplifier. Further measurements indicated that most of this field noise probably originates with dielectric losses in the cryostat’s fibreglass shells.     

A comparative study of fatigue behaviour of flax/epoxy and glass/epoxy composites

Experimental investigations on flax and glass fabrics reinforced epoxy specimens, i.e. FFRE and GFRE, submitted to fatigue tests are presented in this paper. Samples having [0/90]_3S and [±45]_3S stacking sequences, with similar fibre volume fractions have been tested under tension–tension fatigue loading. The specific stress-number of cycles to failure (S–N) curves, show that for the [0/90]_3S specimens, FFRE have lower fatigue endurance than GFRE, but the [±45]_3S FFRE specimens offer better specific fatigue endurance than similar GFRE, in the studied life range (<2 × 10⁶). Overall, the three-stage stiffness degradation is observed in all cases except for [0/90]_3S FFRE specimens, which present a stiffening phenomenon of around 2–3% which could be related to the straightening of the microfibrils.     

Dynamic simulation of the helium refrigerator/liquefier for LHD

A real-time dynamic simulation has been carried out for the 10 kW class helium refrigerator/liquefier of Large Helical Device (LHD) at National Institute for Fusion Science (NIFS). The refrigerator consists of eight screw compressors, seven expansion turbines, fourteen heat exchangers and a 20 m³ liquid helium reservoir. A simulation model was implemented to Cryogenic Process REal-time SimulaTor (C-PREST), developed as a platform for the plant process study and optimization. Validity of the simulation model has been confirmed based on the design values as well as the results of commissioning tests. This paper describes the cooldown process and expansion turbine trips during the operation. Difficulties of dynamic simulation for the large cryoplant are also discussed.     

Mode III fatigue delamination growth of glass fiber reinforced polymer woven laminates at cryogenic temperatures

This paper investigates the cryogenic fatigue delamination behavior of glass fiber reinforced polymer woven laminates under Mode III loading. Fatigue delamination tests were conducted using split cantilever beam specimens at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K). A finite element analysis was also employed to calculate the energy release rate. The temperature dependence of the fatigue delamination growth rate vs. energy release rate range is discussed. Fracture surfaces were examined by scanning electron microscopy to identify the delamination mechanisms under fatigue loading. The important conclusion we reach is that the Mode III fatigue delamination growth rates of woven laminates at cryogenic temperatures are lower than that at room temperature.     

Materials modeling and finite element simulation of isothermal forging of electrolytic copper

Isothermal forging of electrolytic copper is modeled using finite element simulation and materials models involving kinetic analysis and processing maps with a view to validate their predictions. Forging experiments were conducted on a rib–web (cup) shape in the temperature range of 300–800 °C and at speeds of 0.01–10 mm s⁻¹. The processing map for hot working of electrolytic copper revealed two domains in the temperature and strain ranges of (1) 400–600 °C and 0.001–0.01 s⁻¹, (2) 650–950 °C and 0.3–30 s⁻¹, where dislocation core diffusion and lattice self-diffusion are the rate-controlling mechanisms, respectively. Finite element simulation using the relevant experimental constitutive equations, predicted load–stroke curves that correlated well with the experimental data. The simulation has shown that there is a strain variation from about 0.4 to 4 in the web and rib regions of the forged component, although the dynamically recrystallized grain structure is fairly uniform, suggesting that dynamic recrystallization (DRX) is not sensitive to strain once the steady state flow is reached. The DRX grain size in the component is linearly dependent on Z and is similar to that predicted by the materials model after discounting for the longer time taken for the component removal.     

Effect of frequency on fatigue crack growth behavior of magnesium alloy AZ61 under immersed 3.5 mass% NaCl environment

Fatigue crack growth test of AZ61 magnesium alloy was carried out under immersed NaCl environment at frequencies of 15, 5 and 0.5 Hz under a stress ratio of 0.1. In order to investigate the effect of frequency on fatigue crack growth behavior in detail, additional tests at frequencies ranged from 15 to 0.01 Hz were conducted under a constant ΔK of 3.25 MPa m^1/2. Effect of frequency was clearly observed in low ΔK region, where fatigue crack growth rate decreased with decreasing frequency. Crack closure would be a dominant factor for the frequency effect observed under immersed NaCl environment at frequencies ranged from 15 to 0.5 Hz. However, fatigue crack growth rates at frequencies lower than 0.05 Hz were higher than those at frequencies higher than 0.5 Hz. The accelerated fatigue crack growth rates at frequencies lower than 0.05 Hz would be attributed to the corrosion attack at the crack tip.     

Very-low temperature specific heat of Torlon

The specific heat of Torlon has been measured in the 0.15-4.2 K temperature range. Data below 1 K can be represented by c(T) = P₁T^1+δ + P₂T³, with P₁ = (5.41 ± 0.08)·10⁻⁶J K^−(2+δ) g⁻¹, P₂ = (2.82 ± 0.03) ·10⁻⁵JK⁻⁴g⁻¹ and δ = 0.28 ± 0.01, as predicted by the tunnelling theory. Above 1 K, the behaviour of c(T) is similar to that of other amorphous materials and can be expressed as: c(T) = P · T^Ω with P = (2.68 ± 0.07)·10⁻⁵JK^Ω+1g⁻¹ and Ω = 3.32 ± 0.02.     

Thermal design of the CFRP support struts for the spatial framework of the Herschel Space Observatory

Thermal finite element (FE) models, of low thermal conductance struts which are required to provide support for the low temperature components of the Herschel Space Observatory, have been validated by measurements at temperatures below 20 K. The Herschel Space Observatory structure is introduced. FE modelling of two designs of support strut is briefly discussed and the final designs presented. Validation of the design models was made in two experiments. The first of these provided specific thermal conductivity data for component CFRP materials, whose composition was initially designed on the basis of data available in the literature. The second experiment was performed to confirm the thermal conductance (Q′/ΔT), of the completed struts. The validation test rigs are described together with details of the experimental methods employed. Values of conductance were at the level of 5 × 10⁻⁵ W/K at a mean temperature of 6 K. The measured data are presented and discussed with reference to the thermal models. Sources of measurement inaccuracy, are also discussed.     

Structural, electrical and optical properties of Ga-doped ZnO films on cyclo-olefin polymer substrates

Ga-doped ZnO (GZO) films with a thickness of 100 nm were prepared on cyclo-olefin polymer (COP) and glass substrates at various temperatures below 100 °C by ion plating with direct-current arc discharge. The dependences of the characteristics of GZO films on the substrate temperature Ts were investigated. All the polycrystalline GZO films, which exhibited a high average visible transmittance of greater than 86%, were crystallized with a wurtzite structure oriented along the c-axis. The lowest resistivities of the GZO films were 5.3 × 10^− 4 Ωcm on the glass substrate and 5.9 × 10^− 4 Ωcm on the COP substrate.     

Synthesis and electrochemical performance of LiV3O8/carbon nanosheet composite as cathode material for lithium-ion batteries

To improve the rate capability and cyclability of LiV₃O₈ cathode for Li-ion batteries, LiV₃O₈ was modified by forming LiV₃O₈/carbon nanosheet composite. The LiV₃O₈/carbon nanosheet composite was successfully achieved via a hydrothermal route followed by a carbon coating process. The morphology and structural properties of the samples were investigated by X-ray diffraction (XRD), thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). TEM observations demonstrated that LiV₃O₈/carbon composite has a very flat sheet-like morphology, with each nanosheet having a smooth surface and a typical length of 400-700 nm, width of 200-350 nm, and thickness of 10-50 nm. Each sheet was surrounded by a thick layer of amorphous carbon. Electrochemical tests showed that the LiV₃O₈/carbon composite cathode features long-term cycling stability (194 mAh g⁻¹ at 0.2 C after 100 cycles) and excellent rate capability (110 mAh g⁻¹ at 5 C, 104 mAh g⁻¹ at 10 C, and 82 mAh g⁻¹ at 20 C after 250 cycles). Electrochemical impedance spectra (EIS) indicated that the LiV₃O₈/carbon composite electrode has very low charge-transfer resistance compared with pristine LiV₃O₈, indicating the enhanced ionic conductivity of the LiV₃O₈/carbon composite. The enhanced cycling stability is attributed to the fact that the LiV₃O₈/carbon composite can prevent the aggregation of active materials, accommodate the large volume variation, and maintain good electronic contact.     

Fatigue and cyclic creep of replicated microcellular aluminium

The cyclic behaviour of 400 μm pore size replicated aluminium foam is assessed in tension-tension fatigue with a stress ratio equal to 0.1, keeping the load amplitude constant, for relative density values comprised between 0.175 and 0.220. The number of cycles to failure ranges from 6 × 10² (lowest relative density) to 5 × 10⁶ (highest relative density). The foams display cyclic creep coupled with a strong influence of relative density on their general fatigue performance. Data analysis shows that the foam fatigue behaviour is dominated by cyclic creep, which governs both the deformation and the fatigue life of the cycled specimens, yielding characteristics globally in line with what is expected knowing the metal making the foam.