Constant Amplitude Tests Research Articles

Methodology for Hydrogen-Assisted Fatigue Testing Using In Situ Cathodic Charging

With hydrogen being a promising candidate for many future and current energy applications, there is a need for material-testing solutions, which can represent hydrogen charging under superimposed mechanical loading. Usage of high purity gaseous hydrogen under high pressure in commercial solutions entails huge costs and also potential safety concerns. Therefore, a setup was developed utilizing a customized electrochemical charging cell built into a dynamic testing system. With this setup, two heat treatment states of AISI 4140 (DIN 1.7225, 42CrMo4) with varying yield and ultimate tensile strength were characterized in constant amplitude tests. S-N (Woehler) curves differ between heat-treated states, and when comparing testing in air with in situ cathodic hydrogen-charged specimens, hydrogen proves to be detrimental to the material properties. For both states considered, the presence of hydrogen leads to a reduction in fatigue life. Fractographic analyses by scanning electron microscopy reveals that for in situ cathodic hydrogen-charged specimens, the crack initiation mechanisms change for the higher strength heat treatment state.

Fatigue performance of stainless steel bolts in tension under variable amplitude loading

This study experimentally investigates the variable amplitude fatigue performance of A4–70 stainless steel bolts under axial tensile loading. Static tests were first performed to establish the load-axial elongation relationship. Constant amplitude and variable amplitude fatigue tests were subsequently conducted to obtain the fatigue loading cycles and failure modes. The fracture surfaces were inspected via macroscopic and microscopic morphology analyses. The fatigue performance was eventually evaluated in terms of SN data, and the equivalent fatigue strength of the bolts under variable amplitude loading was calculated based on their cumulative damages. The predictions of several international design codes for bolt fatigue were compared with the test results to verify the feasibility of these provisions. The results of the study showed that the bolt fracture surfaces possess significant morphology features representing the respective fatigue damage progresses. The fatigue performance of the stainless steel bolts under variable amplitude loading is influenced by the loading sequence and load amplitude. Current design codes can provide conservative predictions of the fatigue life of A4–70 stainless steel bolts in tension.

Fatigue Failure of Adhesive Joints in Fiber-Reinforced Composite Material Under Step/Variable Amplitude Loading—A Critical Literature Review

Most fatigue-loading research has concentrated on constant-amplitude tests, which seldom represent actual service conditions. Because of the significant time and expense associated with variable-amplitude experiments, researchers often employ block/step-loading tests to evaluate the effects of variable-amplitude loading. These tests utilize various sequences of low-to-high and high-to-low loads to simulate real-world scenarios. Empirical investigations have shown inconsistencies in the damage accumulation under different load sequences. Although literature reviews exist for simulation and experimental methods, there is limited research examining the impact of step/variable-amplitude loading on adhesive joints in composite materials. This review aims to address this gap by comprehensively analyzing the effects of load sequence and block loading on fatigue damage progression in fiber-reinforced polymer composites. Additionally, the applicability of various step-loading fatigue damage accumulation models to adhesive materials is evaluated through numerical simulation to study its suitability in predicting fatigue failure. This review also explores recent theoretical advancements in this field over the past few years, examining more than 100 fatigue damage accumulation models categorized into seven subcategories: (i) linear damage rules, (ii) nonlinear damage curve and two-stage linearization models, (iii) life curve modification models, (iv) models based on crack growth concepts, (v) continuum damage mechanics-based models, (vi) material degradation models, and (vii) energy-based models. Finally, numerical simulations using the most common nonlinear cumulative fatigue damage accumulation models were conducted to predict fatigue failure in adhesively bonded joints under four step-loading tests, and the results were compared with the experimental data. Numerical simulations revealed the need and scope of further development of a fatigue failure model under step/variable loading. This comprehensive review offers valuable insights into the complex nature of fatigue failure in adhesive joints under variable loading conditions and highlights current state-of-the-art nonlinear fatigue damage accumulation models for adhesive materials.

Crack Growth Analytical Model Considering the Crack Growth Resistance Parameter Due to the Unloading Process

Crack growth analysis is essential for probabilistic damage tolerance assessment of aeroengine life-limited parts. Traditional crack growth models directly establish the stress ratio–crack growth rate or crack opening stress relationship and focus less on changes in the crack tip stress field and its influence, so the resolution and accuracy of maneuvering flight load spectral analysis are limited. To improve the accuracy and convenience of analysis, a parameter considering the effect of unloading amount on crack propagation resistance is proposed, and the corresponding analytical model is established. The corresponding process for acquiring the model parameters through the constant amplitude test data of a Ti-6AL-4V compact tension specimen is presented. Six kinds of flight load spectra with inserted load pairs with different stress ratios and repetition times are tested to verify the accuracy of the proposed model. All the deviations between the proposed model and test life results are less than 10%, which demonstrates the superiority of the proposed model over the crack closure and Walker-based models in addressing relevant loading spectra. The proposed analytical model provides new insights for the safety of aeroengine life-limited parts.

Assessment of internal defects in flush ground butt welds in marine structures

In this paper, acceptance criteria of internal planar defects for the highest design S-N curve for surface ground butt welds in fatigue design standards has been assessed based on fatigue tests of tethers containing internal defects. The results from crack growth analysis from defects placed close to the surface are compared with test data from constant amplitude testing of tethers with circumferential welds that includes flaws or small planar defects close to the surface. Floating structures and support structures are subjected to variable loads and the calculated response leads to a long-term stress range distribution with many small stress ranges. This means that if the cracks are small, the resulting stress intensity may be less than the threshold stress intensity factor and the crack does not grow for this stress cycle, or it grows at a reduced crack growth rate in the near threshold region. A methodology to account for this is presented based on a two-parameter Weibull long-term stress range distribution that is representative for load response of floating structures and for support structures for wind turbines. It is shown that the threshold value and the reduced crack growth rate in the near threshold region for small internal defect heights can be used to lift the fatigue test data from constant amplitude testing to be in better correspondence with a higher S-N curve when considering an actual long-term loading.

Model tests on chain-soil interaction of anchor pile for taut mooring system through transparent sand

The pile response of taut mooring systems considering chain-soil interactions remains unclear. In this study, model tests on the performance of anchor piles and the surrounding soil displacement field were conducted using transparent sand. Cyclic motion was imposed at the top end of the chain. The effects of pad eye location (z), motion velocity (v), motion amplitude (A), and amplitude increment (Ai) are discussed. In the constant-amplitude tests, the soil displacement caused by chain motion was apparent near the dip-down point, and the soil displacement increased with z and A. The maximum chain tension decreased owing to chain-soil interactions. The maximum tension with z = 0.55L and 0.67L (where L is the pile length) increased 9% and 15%, respectively, compared with that with z = 0.40L, and the maximum tensions at A = 80 and 120 mm decreased 15% and 29%, respectively, of that at A = 40 mm. In the incremental-amplitude tests, soil displacement was evident around the dip-down point and pile. The maximum tension during each cycle increased almost linearly with the number of cycles before pile failure, and the maximum tension during the entire test increased with z and v.

Thermomechanical fatigue behavior of CF/PEKK composite under low and ultrasonic frequencies

This study aimed to extract the thermomechanical fatigue behavior of a CF/PEKK composite under low and ultrasonic frequency fatigue tests (LFFTs and UFFTs) in the presence of the self-heating effect. Preliminary increasing amplitude tests (IATs) were performed to obtain the minimum load level at which the self-heating is observable. Extracting the fatigue strength from T-σ curves for three mean stress levels resulted in constructing S-N curves for the LFFT regime at different load levels using a shift procedure. However, combining LFFT and UFFT results via S-N curve was impractical, while joining such results through the heat dissipation rate (q̇) was feasible for various constant amplitude tests and IATs. The derived σ-q̇ curves from combining LFFT and UFFT results and comparing the fracture mechanisms of CF/PEKK composite using fractography would make a step for bridging the transition zone between LFFTs and UFFTs and making the results transferable. The microscopy images obtained from fractography also confirmed the similarities of fatigue fracture mechanisms between LFFTs and UFFTs.

Cyclic loading behavior of concrete with thermally-induced damage

The paper reports a study on concrete specimens that were subjected to constant amplitude, low-strain cyclic (LSC) and high-strain cyclic (HSC) tests to evaluate their cyclic behavior after they had been subjected to either ambient or elevated temperatures. Parameters examined included maximum normal stress, dynamic modulus, and extent of damage observed in specimens. An equation is proposed to help quantify the extent of damage in specimens, which accounts for both thermal and cyclic loading effects. Ultrasonic Pulse Velocity (UPV) measurements were also used to quantify the damage in both the LSC and HSC tests. Results show that losses in compressive strength and dynamic modulus are greater in cases with higher temperature exposures due to thermally induced damages. Also, cyclic characteristics of the specimens were found to be significantly influenced by the strain amplitude used in cyclic loading tests.

Digital Image Correlation Structural Strain Analysis of S235 Fillet-Welded Joints under Low-Cycle Fatigue Loadings

The main objectives of the present study were the application and validation of the newly proposed Digital Image Correlation equivalent structural strain approach for assessing the low-cycle fatigue life of S235 welded joints. Low-cycle fatigue tests were performed at a displacement ratio of minus one. Experimental tests were performed using two different ways of controlling the displacement amplitude: applying traditional low-cycle fatigue tests at a constant amplitude and stepwise succession tests at increasing amplitudes. A comprehensive, independent experimental procedure, proposed by the authors and not yet validated for steel welded joints, was applied to assess the equivalent structural strain range using the Digital Image Correlation technique for the traditional low-cycle fatigue tests and stepwise succession tests at increasing amplitudes. It is noteworthy that the values of the DIC equivalent structural strain (ΔEs from the DIC), calculated on the external sides of the samples, were utilized to predict fatigue life in correlation with the ASME mean curve and fall within the ±3σ scatter bands (external bands). In particular, most of the tests lie within the ±2σ boundary of the design curves except for some tests at low applied displacements. Moreover, it was shown that this method is applicable to stepwise succession tests with increasing displacement amplitudes, leading to significant time savings compared to conventional experimental tests.

Influence of hot-dip galvanization on the fatigue performance of high-strength bolted connections

In the present work, the influence of hot-dip galvanization (HDG) on the fatigue behaviour of high-strength bolted details is investigated through a set of 15 constant-amplitude tests. Cyclic behaviour of coated specimens is hence compared against results for unprotected samples drawn from literature, i.e., both with reference to neutral and aggressive exposure conditions. Namely, while behaviour of coated samples is moderately inferior as respect to uncoated ones in dry air (–6 % in terms of characteristic fatigue strength, probability of failure PF = 5 %, confidence interval CI = 75 %), their performance still complies with European normative requirements for double covered joints, and galvanization proves to be highly effective when corrosion is likely to occur (with a characteristic strength increase of [+12 %; +52 %]). Finally, fractography analyses on both uncoated and coated specimens were performed, suggesting that hydrogen embrittlement may play a role in reducing fatigue strength of coated joints, that is, especially within the high-cycle fatigue regime.

Fatigue life evaluation of metastable austenitic stainless steel AISI 347 based on nondestructive testing methods for different environmental conditions

Due to aging nuclear power plants there is an increasing need for methods to evaluate the integrity of components and structures of nuclear engineering. During power plant operation, nuclear materials are exposed to the effects of temperature, corrosion and cyclic loading. These lead to microstructural changes resulting in material degradation, which can be detected by suitable nondestructive testing (NDT) methods. Fatigue testing setups for ambient temperature, distilled water and 300 °C were designed to represent relevant environmental conditions and instrumented with in-situ measurements of temperature, electric, micromagnetic and electrochemical NDT parameters. Constant amplitude and strain increase tests with specimens of metastable austenitic stainless steel AISI 347 (X6CrNiNb18-10, 1.4550) typically used for pipe components were conducted in total strain control. Data obtained were employed in short-time evaluation procedure StrainLife to generate fatigue life data. To establish an understanding between microstructure evolution and NDT data, scanning electron microscopic methods such as electron backscatter diffraction and energy dispersive X-ray spectroscopy were used. Electrochemical data yields fatigue life results as good as conventionally used parameters like stress and strain. These findings could enable usage of presented parameters for mobile or even online testing systems, since accessibility depending on application case can be much improved.

Fatigue strength estimation of a CF/PEKK composite through self-heating temperature analysis using cyclic bending tests at 20 kHz

Very high cycle fatigue (VHCF) testing at conventional frequencies is highly time-consuming and unrealistic for large sample sizes. Though testing at ultrasonic frequencies can accelerate the testing, any undesirable thermal effect arising from testing at 20 kHz can cause significant heat generation in the specimens, increasing the likelihood of thermally induced failure. When mitigated, the temperature behavior during ultrasonic fatigue testing may conversely provide knowledge of the fatigue behavior of the composite. We study this hypothesis in this work by estimating the fatigue strength of a CF/PEKK composite through its temperature evolution during 3-point bending tests at 20 kHz with different cyclic load amplitudes. The fatigue strength of the composite was estimated using the temperature characteristics from an increasing cyclic amplitude test. This estimation was validated with four constant cyclic amplitude tests. Further, the estimation model was extended to different pulse–pause sequences by two constant cyclic amplitude tests. The results indicate a reliable and rapid method for fatigue life estimation as a material property. Finally, the criticality of the self-heating phenomenon during the non-stationary self-heating condition was evaluated.

StressLife: A Short-Time Approach for the Determination of a Trend S-N Curve in and beyond the HCF Regime for the Steels 20MnMoNi5-5 and SAE 1045.

Within the scope of this research, a new short-time procedure designated as StressLifeHCF was developed. Through a combination of classic fatigue testing and non-destructive monitoring of the material response due to cyclic loading, a process-oriented fatigue life determination can be carried out. A total of two load increases and two constant amplitude tests are required for this procedure. By using data from non-destructive measurements, the parameters of the elastic approach according to Basquin and the plastic approach according to Manson-Coffin were determined and combined within the StressLifeHCF calculation. Furthermore, two additional variations of the StressLifeHCF method were developed in order to be able to accurately describe the S-N curve over a wider range. The main focus of this research was 20MnMoNi5-5 steel, which is a ferritic-bainitic steel (1.6310). This steel is widely used for spraylines in German nuclear power plants. In order to validate the findings, tests were also performed on an SAE 1045 steel (1.1191).

Fatigue condition monitoring of notched thermoplastic-based hybrid fiber metal laminates using electrical resistance measurement and digital image correlation

In this work, the monitorability of fatigue damage in notched thermoplastic-based hybrid fiber metal laminate, containing AA6082-T4 sheets and glass and carbon fiber-reinforced polyamide 6, is investigated using constant amplitude tests. Electrical resistance measurement and digital image correlation were combined to determine the initiation and evolution process of fatigue damage. Preliminary to the application of the electrical resistance measurement during fatigue load, basic investigations regarding necessary measurement accuracy and conditions, e.g. temperature and cross-section influence, were conducted to achieve reliable measurement results. Via digital image correlation fatigue crack growth was determined and correlated with the change in electrical resistance for two metal/fiber-reinforced polymer layer configurations (2/1 and 3/2) and notch geometries (drilling hole and double-edge notch). The results show that reliable detection of fatigue-related damage states is possible independent of aluminum sheet treatment (mechanically blasted or anodized surface), with earlier crack initiation and faster propagation for higher metal volume fraction (layer configuration 2/1). For the two investigated notch geometries an overall similar crack behavior was found. The electrical resistance values directly correlate to varieties of crack formation and growth, representing the aluminum sheet damage progress of the laminate well, and enabling the possibility of e.g. a limit value-based failure criterion. However, geometry and crack-related changes in electric current flow and thus current density must be taken into account for targeted monitoring of the laminate condition, as they cause significant changes in electrical resistance.

Intralaminar crack growth rates of a glass fibre multiaxial laminate subjected to variable amplitude loading

The literature shows that variable amplitude loading can be much more severe than constant amplitude loading in a fatigue damage context. However, the underlying physical explanations for this are still unknown. Therefore, this paper investigates if the local energy release rate at each intralaminar crack tip in a tension/tension fatigue loaded multidirectional laminate can be used to determine the crack growth rate of these cracks subjected to variable amplitude loading. The local energy release rate is investigated through a developed finite element model in which any number of cracks can be included to account for their interaction. The position of the cracks is determined based on previous experimental work. The experimental results from the previous work are compared to the numerical results in this work. At similar crack density levels the energy release rates increase in the variable amplitude tests compared to constant amplitude tests, but not enough to significantly impact the crack growth rate. It is concluded that less than 5% of the increased crack density rate and crack growth rate caused by variable amplitude block loading is due to increases in local energy release rate. The primary reason is more likely found on a microstructural level.

Short-Time Fatigue Life Estimation for Heat Treated Low Carbon Steels by Applying Electrical Resistance and Magnetic Barkhausen Noise

Tensile tests and fatigue tests on differently heat-treated low carbon (non- and low-alloy) steels were conducted and accompanied by non-destructive electrical resistometric (ER) and magnetic Barkhausen noise (MBN) measuring devices, in order to establish an improved short-time fatigue life estimation method according to StressLife. MaRePLife (Material Response Partitioning) is the hereby proposed method for calculating S-N curves in the HCF regime, based on the partitioning of material responses acquired during the above-mentioned mechanical tests. The rules were set to make use of the information gathered from pre-conducted tensile tests, which helps to determine the parameters of two load increase tests (LIT) and two constant amplitude tests (CAT). The results of the calculated S-N curves were satisfactory and could be verified by more separately conducted fatigue tests on specimens under different material conditions.

A new procedure for fatigue life prediction of CFRP relying on the first amplitude harmonic of the temperature signal

The use of thermal indexes assessed by monitoring rapid fatigue tests with infrared detectors as reliable damage parameters to reconstruct S/N curve is a topic still presenting open points. First of all, the selection of the proper thermal index representing damage is a topic to be explored and also the relationship between the damage from rapid stepwise test and constant amplitude test is another a point of discussion.In the present work, we deal with such an issue by investigating the First Amplitude Harmonic (FAH) of thermal signal related to thermoelastic phenomena and dissipative effects too. It has been demonstrated that FAH is related to stiffness degradation and stress induced effects. Moreover, it provides a local analysis of the specific effect related to the material fatigue damage without artifacts.The results show that due to relationship between stiffness degradation and FAH, and specific material properties it is possible to reconstruct S/N curve by carrying out just one constant amplitude test and stepwise rapid tests. Moreover, the capability of temperature FAH to study fatigue behaviour and detect damage during any loading procedure, are also presented.

Characterization of the Fatigue Behaviour of Low Carbon Steels by Means of Temperature and Micromagnetic Measurements

Investigations on low carbon (non- and low-alloy) steels were conducted in form of load increase tests (LIT) and constant amplitude tests (CAT) to find the correlation among material behaviour, mechanical load, and the type of NDT method. With the help of preprogrammed load-free sequences, the thermal impact on magnetic Barkhausen noise (MBN) measurement can be avoided, so that the cyclic deformation properties of material responses can be interpreted more precisely. The results indicate differences between the change in temperature and the MBN-derived variable during LITs and CATs regarding the demonstration of the incubation stage and the cyclic hardening behaviour.

Defect-based characterization of the fatigue behavior of additively manufactured titanium aluminides

The additively manufactured titanium aluminide alloy TNM-B1 was characterized microstructurally and mechanically in the as-built and hot isostatically pressed (HIP) condition. Tensile and constant amplitude tests were performed at room temperature and 800 °C. Using fractographic SEM images, the fracture-inducing defect was identified. With the HIP, defect number and size could be reduced, increasing fatigue strength by 43% to 500 MPa. Using the model approaches of Murakami and Shiozawa, the fatigue life was correlated with the local stress intensity factor and could be described as function of the stress amplitude as well as the size and location of fracture-inducing defects.

Improving brace member seismic performance with amplified-deformation lever-armed dampers

This study focused on the development and validation of a novel brace design that incorporated a hinged truss member and a set of lever-armed damper (LAD), namely LAD-Brace, for structural performance enhancement. The lever-armed damper was designed with adequate rotation mechanism to generate amplified-deformation and uniform yield zones in the tapered energy dissipation plate for efficient energy dissipation. A series of cyclic loads and constant peak amplitude tests were conducted on LAD-Braces with various geometries in the energy dissipation plates. Analytical expressions for yield strength estimation were derived and effectively validated by the test results. Cyclic load test results showed that adequate strength, effective equivalent viscous damping and significant energy dissipation were simultaneously achieved which justified the design applicability for earthquake-resistant purposes. Investigation through constant peak amplitude tests revealed that LAD-Braces, when designed with adequate geometries, possessed further seismic resilience after experiencing major earthquake excitation, thus validated the proposed design effectiveness and robustness.