Impact–fatigue behaviour of unidirectional carbon fibre reinforced polyetherimide (PEI) composites

Impact fatigue properties of unidirectional carbon fibre-reinforced polyetherimide (PEI) composites was evaluated by subjecting standard izod impact samples to low velocity impact loading at energy levels ranging 0.16–1.08 J by using Ceast Model Resil 25, a pendulum type instrumented impact test system. The effect of the previous low velocity impacts on the impact properties of the laminates was investigated. On the other hand materials were subjected to repeated low velocity impact tests up to fracture. Results of repeated impact study are reported in terms of peak load, absorbed energy and number of impacts. Fractographic analysis revealed the fracture by primary debonding, with fibre breakage and pullout in the tensile zone, but a shear fracture of fibre bundles in the compressive zone of the specimen.     

Static and impact fatigue behaviour of borosilicate glass

Failure of a borosilicate glass as a result of repeated impact has been studied. Impact fatigue study was conducted in an improved pendulum type repeated impact apparatus specially designed and fabricated for determining single and repeated impact strength. For elimination of the effect of humidity, repeated impact tests were carried out under liquid nitrogen. Quasi-static measurements were determined under four-point bending. Using a square waveform as applicable to the present impact tests and fracture mechanics interpretation, the number of cycles to failure during impact fatigue tests were predicted from quasi-static fatigue measurements. It has been shown that repeated impact loading has a deleterious effect on the failure cycles compared to slow stressing. The role of an added mechanical effect during repeated impacts has been suggested in controlling the cyclic fatigue behaviour. Paper presented at the poster session of MRSI AGM VI, Kharagpur, 1995     

Impact fatigue behaviour of carbon fibre-reinforced vinylester resin composites

Two types of unidirectional carbon fibre, one of high strength (DHMS) and another of medium strength (VLMS) reinforced vinylester resin composites have been examined for their impact fatigue behaviour over 10⁴ impact cycles for the first time. The study was conducted using a pendulum type repeated impact apparatus specially designed and constructed for the purpose. A well-defined impact fatigue behaviour (S-N type curve) curve has been demonstrated. It showed a plateau region of 10–10² cycles immediately below the single cycle impact strength, followed by progressive endurance with decreasing impact loads, culminating in an endurance limit at about 71% and 85% of the single impact strength for DHMS-48 and VLMS-48, respectively. Analysis of the fractured surfaces revealed primary debonding, fibre breakage and pull-out at the tensile zone of the samples and a shear mode of fracture with breakage of fibre bundles at the compressive zone of the samples. The occurrence of a few major macrocracks in the matrix with fibre breakage at the high load-low endurance region and development of multiple microcracks in the matrix, coalescing and fibre breakage at the low-load-high endurance region have been inferred to explain the fatigue behaviour of the composites examined.     

Evolution of residual stresses with fatigue crack growth in integral structures with crack retarders

Bonded straps are investigated for their ability to retard a growing fatigue crack in metallic structures. The evolution of the residual stresses in the vicinity of the strap with fatigue crack growth has been studied. Cracks were grown in single edge-notched tension (SEN(T)) specimens reinforced with either a titanium or a carbon fibre reinforced plastics (CFRP) strap. The residual stress evolution has been measured in situ during crack growth using neutron diffraction, and modelled with a finite element approach. The peak residual stresses induced by the mismatch of the coefficient of thermal expansion between the strap and plate materials were seen to be fairly constant with crack growth. Good correlation between the experimental and the modelling results was found, except at very long crack lengths for a specimen that exhibited considerable fracture surface roughness at long crack lengths. The difference was attributed to wedging of the fracture surface changing the expected stress state, rather than any effect of the strap.     

Residual stress effect on impact properties of Gr/Al metal matrix composite

The effects of residual stress on the impact properties of the unidirectionally reinforced P 100 Gr/6061 Al metal matrix composites with different thermal histories have been investigated using an instrumented impact test method and scanning electron microscopy. The cantilever impact generally causes tensile failure at the notch and compressive loading on the opposite side of the specimen. The specimens with yield tensile matrix residual stresses have planar fracture surfaces and low impact energy due to the contribution of tensile residual stress. The specimens with small residual stresses have moderate impact energy because debonding between fibre and matrix or fibre/matrix separation also serves as an additional mechanism for energy absorption. The specimens with higher compressive matrix residual stresses have the largest maximum load of all the specimens with the same matrix treatment. The specimen with matrix compressive yield residual stress has the maximum impact energy owing to a stepwise fracture surface. It can be concluded that good impact properties of composite materials can be obtained by choosing a suitable thermal history to modify the deleterious tensile matrix residual stress.     

Fatigue crack initiation assessment of welded joints accounting for residual stress

The impact of residual stresses on the fatigue crack initiation life of welded joints is evaluated by the finite element method. The residual stresses of nonload‐carrying cruciform joints, induced by welding and ultrasonic impact treatment, are modelled by initial stresses, using the linear superposition principle. An alternative approach of using modified stress‐strain curves in the highly stressed zone is also proposed to account for the residual stress effect on the local stress‐strain history. An evaluation of the fatigue crack initiation life of welded joints based on the local strain approach is carried out. The predicted results show the effect of residual stresses and agree well with published experimental results of as‐welded and ultrasonic impact treated specimens, demonstrating the applicability of both approaches. The proposed approaches may provide effective tools to evaluate the residual stress effect on the fatigue crack initiation life of welded joints.     

Influence of Impact on the Mechanical Behaviour of the Gamma‐Based TiAl Alloy TNBV3B

The quasi‐static and fatigue behavior after impact of the TiAl alloy TNBV3B produced via three different processing routes—cast, forged and extruded—has been studied on flat and airfoil‐like shaped specimens making use of ballistic impact experiments. For impacts resulting in cracks the behavior can be described using a linear‐elastic fracture mechanics approach. The residual strength is described on the basis of the fracture toughness. The residual fatigue strength of impact‐cracked specimens is estimated on the basis of the threshold for crack growth of the TNBV3B alloys. However, when there is no visible crack or when the crack length is below the size of the deformed impact area, residual stresses and micro‐damage play a dominating role making the linear‐elastic fracture mechanics approach invalid. The deformation hardened zone in TiAl has been studied making use of micro‐hardness tests showing their extension and the degrees of deformation for different impact energies.     

Stresses in bent copper tubing: Application to fatigue and stress-corrosion cracking failure mechanisms

The residual and applied stresses in u-bent copper tubing are addressed in the context of both cyclic fatigue and stress-corrosion cracking. Failures as a result of fatigue and stress corrosion cracking in u-bent copper tubing have been observed to initiate at nonintuitive locations when only the applied stresses on the component are considered. This paper presents both qualitative classical and quantitative finite-element stress analysis results for the forming of u-bends. The resulting residual stress distributions are compared to fracture patterns generated by both fatigue and stress-corrosion cracking mechanisms.     

Cruciform fillet welded joint fatigue strength improvements by weld metal phase transformations

Arc welding typically generates residual tensile stresses in welded joints, leading to deteriorated fatigue performance of these joints. Volume expansion of the weld metal at high temperatures followed by contraction during cooling induces a local tensile residual stress state. A new type of welding wire capable of inducing a local compressive residual stress state by means of controlled martensitic transformation at relatively low temperatures has been studied, and the effects of the transformation temperature and residual stresses on fatigue strength are discussed. In this study, several LTTW (Low Transformation‐Temperature Welding) wires have been developed and investigated to better characterize the effect of phase transformation on residual stress management in welded joints. Non‐load‐carrying cruciform fillet welded joints were prepared for measurement of residual stresses and fatigue testing. The measurement of the residual stresses of the three designed wires reveals a compressive residual stress near the weld toe. The fatigue properties of the new wires are enhanced compared to a commercially available wire.     

Modelling of damage and failure of glass/epoxy composite plates subject to impact fatigue

An investigation has been carried out to study the impact fatigue damage of glass/epoxy laminated composites. Accumulation of damage, such as matrix cracking, delamination and fibre breakage, with repeated impact of the composite material may reduce the overall stiffness. These damage modes have been combined in a very complicated way to describe damage growth and fracture. A model is proposed for characterising the damage as a function of the normalised impact number. The scalar variable D, which characterises the material damage, is written as a function of the life duration β, using a modified form of the Mankowsky empirical law [Int J Solids Struct 32(11) (1995) 1607]. The macroscopic failure mode and the internal damage in laminated specimens of glass/epoxy as a consequence of impact fatigue are analysed at different levels of incident impact energy. The impact fatigue tests have been conducted on an apparatus built in our laboratory.     

Response of notched carbon/PEEK and carbon/epoxy laminates subjected to tension fatigue loading

In this study a comparison is made between the tensile static and fatigue behaviours of quasi-isotropic carbon/PEEK and carbon/epoxy notched laminates, selected as separate representatives of both tough and brittle matrix composites. Damage progression was monitored by various non-destructive (ultrasonic scanning and x-radiography) and destructive (deply and microscopic examinations) techniques, and by continuously measuring the change in stiffness, in order to identify the effect of damage on mechanical properties.
The experimental observations indicated that fatigue damage in carbon/epoxy laminates consists of a combination of matrix cracks, longitudinal splitting and delaminations which attenuate the stress concentration and suppress fibre fracture at the notch; as a consequence, fatigue failure can be reached only after very high numbers of cycles while tensile residual strengths continuously increase over the range of lives investigated (10³–10⁶ cycles). Due to the superior matrix toughness and the high fibre-matrix adhesion, the nature of fatigue damage in carbon/PEEK laminates strongly depends on the stress level. At high stresses the absence of early splitting and delaminations promotes the propagation of fibre fracture therefore resulting in poor fatigue performances and significant strength reductions; while at low stress levels damage modes are matrix controlled and this again translates into very long fatigue lives. These results indicate a strong influence of the major damage mechanisms typical of the two material systems on the behaviour of the laminates, with the nature, more than the amount, of damage appearing as the controlling parameter of the material response up to failure.     

Evaluation of fibre bridging stress of short fatigue cracks in SCS-6/Ti-15-3 composite

Single‐edge notched specimens of a unidirectional SiC long fibre reinforced titanium alloy, were fatigued under four point bending. The propagation behaviour of short fatigue cracks from a notch was observed on the basis of the effects of fibre bridging. The branched fatigue cracks were initiated from the notch root. The fatigue cracks propagated only in the matrix and without fibre breakage. The crack propagation rate decreased with crack extension due to the crack bridging by reinforced fibres. After fatigue testing the loading and residual stresses in the reinforced fibres were measured for the arrested cracks by the X‐ray diffraction method. The longitudinal stresses in the reinforced fibres were measured using high spatial resolution synchrotron radiation. A stress map around the fatigue cracks was then successfully constructed. The longitudinal stress decreased linearly with increasing distance from a location adjacent to the wake of the matrix crack. This region of decreasing stress corresponded to the debonding area between the fibre and the matrix. The interfacial frictional stress between the matrix and the fibre could be determined from the fibre stresses. The bridging stress on the crack wake was also measured as a function of a distance from a notch root. The threshold stress intensity factor range, corrected on the basis of the shielding stress, was similar to the propagation behaviour of the monolithic matrix. Hence the main factor influencing the shielding effect in composites is fibre bridging.     

Fatigue assessment of high‐frequency mechanical impact (HFMI)‐treated welded joints subjected to high mean stresses and spectrum loading

The fatigue strength of welded joints can be improved with various post‐weld treatment methods. High‐frequency mechanical impact treatment is a residual stress modification technique that creates compressive residual stresses at the weld toe. However, these beneficial residual stresses may relax under certain loading conditions. In this paper, previously published fatigue data for butt and fillet welded joints subjected to high stress ratios and variable amplitude cyclic stresses were evaluated in relation to the current International Institute of Welding (IIW) recommendations on fatigue strength improvement and a proposed IIW design guideline for high‐frequency mechanical impact‐treated welded joints. The evaluation showed that the current IIW recommendations resulted in both non‐conservative and overly conservative fatigue strength estimations depending on the applied stress level, whereas the proposed fatigue assessment guideline fitted the current data well.     

Effects of laser peening with different coverage areas on fatigue crack growth properties of 6061-T6 aluminum alloy

The effects of coverage area on fatigue crack growth (FCG) properties of 6061-T6 aluminum alloy subject to multiple laser peening (LP) impacts were investigated. Residual stress, micro-structure and fatigue striation pattern on fracture cross-sections were analyzed. Compressive residual stresses and dense dislocation arrangements can be found in the superficial layer after LP. LP coverage area has a direct influence on FCG properties as verified by different size of shell ridges and fatigue striation spacing on fracture cross-sections. Meanwhile, FCG rate decreases with the increase of compressive residual stresses distribution perpendicular to the crack growth direction in the initial FCG stage.     

Fatigue Resistance of an Anodized and Hardanodized 6082 Aluminum Alloy Depending on the Coating Thickness in the High Cycle Regime

In this study, the high cycle fatigue behavior of an anodized 6082 aluminum alloy is investigated. Main focus is on the most relevant influencing factors for crack initiation and propagation under cyclic loading and damage mechanisms considering coating type, thickness, and residual stresses. The bare substrate is compared to anodized and hardanodized specimens with three coating thicknesses, for each coating type, in the range from 20 to 70 μm. Coating hardness and microstructure as well as residual stresses are analyzed. Fatigue and fracture behavior under alternating tension–compression loading is determined. Dependent on the coating thickness, the fatigue strength is reduced by 8%–50% after anodizing and by 50%–62% after hardanodizing. As the coating thickness is equal to the initial crack length from a fracture mechanical point of view, stress intensities at the crack tips are higher for thicker coatings respectively longer initial crack lengths. Therefore, propagation of fatigue-induced cracks from the coating into the substrate is promoted for a higher coating thickness resulting in premature failure. A significant correlation between the coating thickness and tensile residual stresses induced by both coatings in the subjacent substrate is not found and residual stress influence on the overall fatigue strength is only minor.     

激光喷丸强化对半圆孔件疲劳寿命的影响

为研究激光喷丸强化对7075-T6铝合金半圆孔件疲劳寿命的影响,对激光喷丸与未喷丸的试样进行了对比试验,利用X射线应力仪测定其表面残余应力,并对试样进行疲劳拉伸试验.用扫描电镜观察了两类试样疲劳断口的形貌,并采用数理统计方法对其疲劳寿命进行分析.研究表明:经激光喷丸处理区域,表面存在较大的残余压应力,幅值为310 MPa;未喷丸试样疲劳裂纹条带的宽度为0.7~0.8μm,而喷丸试样疲劳裂纹条带的宽度为0.3~0.4μm,说明喷丸试样裂纹扩展的速度比未喷丸试样慢很多;激光喷丸后半圆孔件的疲劳寿命比未喷丸的疲劳寿命提高了2.8~7.2倍.     

A unified fatigue failure criterion for unidirectional laminates

A unified fatigue failure criterion using micromechanics related to the fracture plane has been developed to predict fatigue lives of unidirectional fibre reinforced polymer composites subjected to cyclic off-axis tension–tension loading. Since the failure criterion incorporates both stresses and strains it may be characterized as energy based. Accounting for the fibre load angle as well as the stress ratio is the novelty of this fatigue failure criterion. The criterion only requires the stress ratio to be known from the experimental procedure. The relation between the applied load and the micro-stress and micro-strain field can be determined from a numerical method. The fatigue failure criterion has been verified by applying it to different sets of experimental data. Several fibre load angles, different fibre/matrix combinations as well as stress ratios are covered. The predicted fatigue lives are in good agreement with the experimental results for both different fibre load angles and stress ratios.     

Influence of foreign object impact mode on fatigue performance of 2198‐T8 Al‐Li alloy thin sheets for fuselage

The 2198‐T8 is the advanced aircraft aluminium‐lithium alloy used for airframe construction. Based on the digital image correlation technique, the postimpact fatigue performance of 2198‐T8 aluminium‐lithium alloy sheets was analysed. The foreign object impact mode includes a single impact, continuous twice‐impacts at the same position and impacts at two parallel positions. For each mode, the collapse behaviours with different impact energies and insert dimensions were investigated. The results could show that residual fatigue life is sensitive to the impact mode, and through digital image correlation (DIC) nephogram analysis, on the surface of dented specimens, there exists the redistribution of strain field. For three types of impact modes, the concept of average damage volume is introduced to fit the effect of dent depth and width on residual fatigue life; the goodness of fit for the whole average damage volume is 89.5%. The crack initiation and propagation of the postimpact fatigue specimen will be affected by the stress concentration and microstructure, and the local multiaxial strain status around the dent will accelerate the crack propagation.     

Impact fatigue of an alumina ceramic

A new type of pendulum impact apparatus is described for determining single and repeated impact strength of ceramics, It has been demonstrated that specimens of a Sintox alumina ceramic exhibit fatigue behaviour, having a high stress plateau followed by progressively increasing endurance with decrease in applied impact energy. A fatigue limit, at least from the engineering view point, has been drawn at high endurances (10⁵ impacts). The influence of environment (static fatigue) and/or plastic deformation to explain the fatigue behaviour is suggested.     

单个冲击对不锈钢管道焊接头低周疲劳寿命的影响

完成了单个冲击对１Ｃｒ１８Ｎｉ９１不锈钢管道焊接头试样低周疲劳寿命影响的试验研究。单个试验最大瞬时峰值应变率达４８０ｓ＾－１。试样未经消除焊接残余应力。采用成组法试验（每组７个试样）,对称加载模式,总应变幅为０．００２２８。结果表明,冲击影响受到焊接残余应力和冲击塑性导入机制的耦合作用。焊接残余应力与冲击应力叠加将增加材料损伤,而冲击塑性导入将减缓疲劳损伤和降低疲劳寿命分散性。前者扼制后者。考虑疲