FATIGUE LIFE ESTIMATION IN RESISTANCE SPOT WELDS: INITIATION AND EARLY GROWTH PHASE

Abstract— The main objective of this research is to develop a model of fatigue crack initiation and early crack growth in resistance spot welds that is specimen independent. This objective is achieved by examining the stress state around a resistance spot weld. A general expression for the structural stress around the weld is formulated that is dependent only on the loading immediately surrounding the weld. As such, it is specimen independent.
An additional objective is to explore the feasibility of applying this fatigue crack initiation model of life estimation using structural response data from finite element analysis (FEA). This numerical technique is often used for evaluating structural integrity of assemblies. Limited verification examples show that the structural stress range as calculated from FEA reaction load data is capable of describing fatigue crack initiation and early crack growth in cyclically loaded resistance spot welds.     

ALGORITHMIC SYNTHESIS OF GENERAL NON-SHARP SIMPLE DISTILLATION COLUMN SEQUENCES

An algorithmic approach was used to select recoveries for non-sharp sequence designs. Simple distillation columns were employed. The non-key component distribution was modeled using the Fenske equation. The combination of producing impure products and allowing non-key component distribution, results in a large search space. With this large search space size and software limitations, five problems were solved (see summary table in the Design Examples sub-section). The optimal non-key component distribution was found to be significant but not necessarily maximal. Parallel processing was selected as optimal in contrast to the more traditional sequential processing.     

Microstructure evolution during mechanical working of three RS aluminium alloys: Al-4Cr-1Fe,Al-5Cr-2Zr and Al-6.43Cr-1.67Zr

Three Al-Cr alloys containing additions of Zr and Fe have been fabricated via cold compaction and hot extrusion. The decomposition of the powder microstructure and the subsequent coarsening during thermomechanical treatment have been studied. Detailed electron microscopy investigations were performed at different locations of partially extruded billets at 450 °C. The microstructure of the dead metal zone reflects the effect the induction heating exerts on the as-atomized powder microstructure. In the low Cr alloys, Al-4Cr-1 Fe and Al-5Cr-2Zr, decomposition of the rapidly solidified microstructure commences at the rich intercellular network, whereas the microstructure of the Al-6.43Cr-1.67Zr alloy remains relatively unaffected. Within the deformation zone the precipitation kinetics are affected by the shearing and the temperature rise. The cells and the powder particles are aligned along the extrusion direction. Precipitation is taking place within the primary segregation-free areas, observed in Al-4Cr-1 Fe and Al-5Cr-2Zr alloys, whereas in the Al-6.43Cr-1.67Zr alloy, decomposition of the powder microstructure starts at the Cr-rich intermetallic particles. The as-extruded microstructure is fibrous and heterogeneous. The heterogeneity of the as-extruded microstructure is a result of the microstructural variation observed within different size powder particles and within individual ones.     

Microstructure of solution-chlorinated polyethylene by 13C nuclear magnetic resonance

Solution-chlorinated polyethylene prepared by a modified method has been characterized using ¹³C nuclear magnetic resonance (n.m.r.) and differential thermal analysis (d.t.a.). The results show that the residual paraffin segments, melting point and crystallinity decrease rapidly with increasing chlorine content. The prepared polymer seems to have a homogeneous chlorine distribution.     

Formation of phase structure and crystallization behavior in blends containing polystyrene–polyethylene block copolymers

The microphase separation structure in the molten state and the structure formation in crystallization from such ordered melt were investigated for the blends of polystyrene–polyethylene block copolymers (SE) with polystyrene homopolymer (PS) and polyethylene homopolymer (PE) and for the blends consisting of two kinds of SE with different copolymer compositions from each other, using synchrotron small-angle X-ray scattering techniques (SAXS). The copolymer compositions of SE block copolymers employed were 0.34, 0.58 and 0.73 wt. fraction of PE, and their melt morphologies were cylindrical, lamellar and lamellar, respectively. Macrophase separation or the morphology change in the melt occurred depending on the molecular weight and the blend composition, as reported so far. In crystallization from such macrophase-separated and microphase-separated melts, the melt morphology was completely kept for all the blends. Crystallization behavior was also investigated for the blends. The crystallization within the spherical and cylindrical domains surrounded by glassy PS was not observed for SE/PS blends. In the crystallization from the macrophase-separated melt, two exothermal peaks were observed in the DSC measurements, while a single peak was observed for other blends. For the blends with PS, the degree of crystallinity was depressed and the apparent activation energy of crystallization was high, compared to those for the corresponding neat SE. For SE/PE and SE/SE blends, those were changed depending on the blend composition.     

Efficiency of mineral admixtures in mortars: Quantification of the physical and chemical effects of fine admixtures in relation with compressive strength

This work is the fourth part of an overall project the aim of which was the development of general mix design rules for concrete containing different kinds of mineral admixtures. The two first parts presented the separation and quantification, by means of an empirical model based on semi-adiabatic calorimetry measurements, of the different physical effects responsible for changes in cement hydration (short terms) when chemically inert quartz powders were used in mortars. Part three dealt with an intensive experimental program, presenting and commenting more than 2000 compressive strength measurements. This program concerned 1 day to 6 months old mortars containing up to 75% of inert and pozzolanic admixtures. All these compressive strength results are analyzed in this fourth part and the influence of three effects, namely dilution, heterogeneous nucleation and the pozzolanic effect, are discriminated and quantitatively evaluated. An efficiency concept is proposed in order to take into account the effect of mineral admixture in mortars from both the physical and chemical points of view. It uses an efficiency function ξ(p) that has notable properties: it is independent of time, independent of fineness and independent of the type of mineral admixture.     

Influence of Atomizing Gases on the Oxide-Film Morphology and Thickness of Aluminum Powders

Fine powders of aluminum were produced in a pilot-plant, inert-gas atomizerwith a confined-design nozzle, which operated vertically upward. Argonand helium at 1.85 MPa and nitrogen at 1.56 MPa were used as the atomizingagent. The morphology of the powder particles was examined by SEM. Powderswere sieved dry and wet. The Sauter mean diameter of the powders varied from20.70 to 10.25 m depending on the atomizing gas. The distribution ofsizes was bimodal. The mean thickness of oxide on the surface of the powderwas calculated from the total oxygen contents of powder samples (determinedby a Leco analyzer). In addition, ESCA measurements and BET tests werecarried out for surface-oxide thickness and area measurements,respectively. The finest powder produced under helium incorporated thinnersurface-oxide layers than the coarser ones produced under argon andnitrogen. This was due to differences in physical properties (such asdensity, thermal conductivity) and flow properties (such as gasvelocity and relative velocity) of the atomizing gases used, i.e., helium,argon, and nitrogen. The oxide was very irregular in thickness in thecoarse-size range of the Al powders produced under argon and nitrogen. Thiswas presumably because of the high- and low-temperature oxidation ofaluminum droplets during the atomization and subsequent solidification andcooling periods leading to the rough surfaces observed with SEMinvestigation in the present work.     

Object Recognition in X-ray Testing Using Adaptive Sparse Representations

In recent years, X-ray screening systems have been used to safeguard environments in which access control is of paramount importance. Security checkpoints have been placed at the entrances to many public places to detect prohibited items such as handguns and explosives. Human operators complete these tasks because automated recognition in baggage inspection is far from perfect. Research and development on X-ray testing is, however, ongoing into new approaches that can be used to aid human operators. This paper attempts to make a contribution to the field of object recognition by proposing a new approach called Adaptive Sparse Representation (XASR+). It consists of two stages: learning and testing. In the learning stage, for each object of training dataset, several patches are extracted from its X-ray images in order to construct representative dictionaries. A stop-list is used to remove very common words of the dictionaries. In the testing stage, test patches of the test image are extracted, and for each test patch a dictionary is built concatenating the ‘best’ representative dictionary of each object. Using this adapted dictionary, each test patch is classified following the Sparse Representation Classification methodology. Finally, the test image is classified by patch voting. Thus, our approach is able to deal with less constrained conditions including some contrast variability, pose, intra-class variability, size of the image and focal distance. We tested the effectiveness of our method for the detection of four different objects. In our experiments, the recognition rate was more than 97 % in each class, and more than 94 % if the object is occluded less than 15 %. Results show that XASR+ deals well with unconstrained conditions, outperforming various representative methods in the literature.     

A critical discussion on rebar electrical continuity and usual interpretation thresholds in the field of half-cell potential measurements in steel reinforced concrete

Corrosion of steel in reinforced concrete structures is a recurrent problem affecting civil engineering structures and costing the world billions of dollars per year. This physical phenomenon mainly results from chloride ingress or concrete carbonation. Corrosion can be diagnosed through a nondestructive method such as half-cell potential measurements. The present paper studies this method on a reinforced concrete wall containing eighteen unconnected steel bars and subjected to chloride-induced macrocell corrosion. Three corrosion systems with different configurations of connections between the steel bars are generated, involving three different anode-to-cathode surface ratios. Then, half-cell potential variations are observed versus macrocell corrosion current. The results lead to a critical discussion regarding the physical relevance of the usual potential threshold method to detect corroding rebars in reinforced concrete structures. In addition, the experiments demonstrate that electrical continuity between reinforcing steel bars is not necessary to get meaningful information about the macrocell corrosion system. At last, the paper show that the electric field (potential gradient) relative to a macrocell corrosion system may be measured by connecting the measurement system (reference electrode?+?voltmeter) to any electrochemical system in electrolytic contact with the concrete.