Development Of Fatigue Cracks Research Articles

Crack Evolvement of Ancient Brick Masonry Under Uniaxial Compression Fatigue Loading

ABSTRACT Cracking is an essential intuitive indicator of damage in masonry structures. Evaluating the progression of fatigue cracks in ancient brick masonry structures is vital for the preservation and safety of ancient buildings. By conducting amplitude cyclic uniaxial compression tests on ancient brick masonry specimens, using the video image correlate-3d (VIC-3D) technology to collect images of the entire process from loading to failure, the development of fatigue cracks is analyzed and concluded. A reversed S-shaped function for fatigue crack evolution was established based on the fatigue damage mechanism. The model parameters’ physical significance, value range, and their impact on the model curve were discussed. The fatigue damage evolution equation was derived from the fatigue crack evolution model. The research results show that a reversed S-shaped function for fatigue crack evolution covers various types of fatigue crack evolution laws, with strong adaptability and high accuracy. The damage evolution curve established, based on the fatigue crack evolution model, has a reversed S-shaped change rule, and was divided into three stages: the first stage (0 N f ~ 0.1 N f ) fatigue damage grows faster; the second stage (0.1 N f ~ 0.9 N f ) fatigue damage growth is stable, close to linear change; when the cycle ratio exceeds 0.9, it enters the third stage, and fatigue damage increases rapidly.

Prediction model of fatigue crack propagation life of corroded steel plate considering pit characteristics

Pitting corrosion notably increases stress concentration, thus accelerating fatigue crack initiation and propagation at the pit base. This research quantifies the relationship between pit dimensions and fatigue crack development by introducing crack extension ratios (γa​ and γc)​. Employing a series of finite element models, the influence of pit characteristics on the stress intensity factor (K) at the crack tip is assessed. Based on these assessments, a formula for computing the K-value is proposed. Furthermore, a two-stage fatigue life prediction model for both partial and complete penetration is developed using the Paris equation. Results indicate that pits substantially affect the K-value during partial penetration. Specifically, as γa approaches zero, the K-value approaches zero, and as γa approaches one, it aligns with the K-value of a semi-elliptical surface crack. Conversely, in the complete penetration phase, the influence of the pit on the K-value is negligible, and the K-value can be calculated according to the plate with a central penetrating crack. Experimental validation confirms that the model generally maintains a prediction error within 10%.

Fatigue and corrosion‐fatigue behavior of the β‐metastable Ti‐5Al‐5Mo‐5V‐3Cr alloy processed by laser powder bed fusion

AbstractWe performed rotating bending tests and axial (tension‐compression) load‐increase and constant amplitude high‐cycle fatigue tests in air and Hanks' balanced salt solution (HBSS) on the β‐metastable titanium alloy Ti‐5Al‐5Mo‐5V‐3Cr, processed by laser powder bed fusion (LPBF‐M), solution‐treated and aged, and shot‐peened. Rotating bending loading in air revealed a strong influence of process‐induced flaws on fatigue endurance. Especially in the high‐cycle fatigue range and the transition region, the stochastic distribution of the flaws and flaw sizes led to a high scatter of the number of cycles to failure. The axial load‐increase tests yielded a good fatigue life estimation, with a negligible difference between air and HBSS. The cyclic deformation behavior in HBSS was also strongly influenced by the local microstructure and defect distribution, and, thus, by crack formation and propagation. Plastic deformation and microcrack growth interact, and their relative amount resulted in different progressions of the plastic strain amplitude over the number of cycles for different specimens. Changes in the free corrosion potential and the corrosion current were highly sensitive indicators for fatigue‐induced damage on the rough surfaces, which was correlated to the microscopic examination, fracture surface features, and the fatigue crack development.

INVESTIGATION OF STRUCTURAL AND MECHANICAL PROPERTIES OF TUBING STEELS

The study of the structural and mechanical properties of tubing steels used in wells at oil and gas condensate fields is of particular interest due to the resource intensity of these systems and the high cost of their repair and restoration. Tubing is operated under conditions of increased loads under the influence of its own weight, internal pressure and constant contact with highly aggressive media. As a result of simultaneous exposure to corrosive media and operational loads, tubing is the most consumable downhole material. The destruction and, as a result, the breakage of the tubing suspension occurs as a result of mechanical abrasion and cracking of the pipe body, the development of fatigue cracks in the thread, etc. Contact with aggressive agents of the extracted fluid and reservoir waters leads to various types of corrosion damage: ulcerative, pitting, corrosion fatigue, corrosion cracking, meza corrosion, biocorrosion, etc. Corrosion foci are localized on the inner and outer surfaces of pipes. The problem is complicated by the increased content of carbon dioxide (CO2), hydrogen sulfide (H2S), as well as the presence of various bacteria in oil and gas fields.This article is devoted to the study of the mechanical characteristics and microstructure of tubing steels that were in operation under conditions of complicating factors and highly aggressive corrosive environment. Tubing pipes Ø73x5.5 of strength group E. were tested. The following research methods were carried out: visual inspection; determination of the chemical composition of steel; determination of hardness; uniaxial tensile test; optical microscopy.As a result of the tests, quantitative characteristics of the mechanical properties of the steels were obtained. A significant decrease in the hardness, tensile strength and yield strength of steel has been established under prolonged exposure to complicated operating conditions. Metallographic studies have established the contamination of steels with silicates of various shapes, amounting to 3 and 2 points according to GOST 1778. Microstructural studies have been carried out. The fine-grained ferrite-carbide structure of steels has been revealed. This structure corresponds to the heat treatment mode: quenching followed by tempering.

Study on the durability deterioration law of marine concrete with nano-particles under the coupled effects of freeze-thaw cycles, flexural fatigue load and Cl− erosion

The marine concrete in cold region such as harbor, wharf and sea-bridge is inevitably subjected to the coupling effects of flexural fatigue load, freeze-thaw cycles and chloride ion (Cl−) erosion. This paper studies the durability of unreinforced concrete under the coupling effects of three factors. And in order to highlight the effects of freeze-thaw cycles, the two-factor coupling durability test of flexural fatigue load and Cl− erosion and the three-factor coupling durability test of freeze-thaw cycles, flexural fatigue load and Cl− erosion are designed. And the microstructures of various concretes are analyzed by mercury intrusion porosimetry (MIP), X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The results show that under the coupling effects of three factors, on the one hand the icing of pore water can improve the deformation resistance of concrete; on the other hand, the expansion pressure can accelerate the deterioration of pores and promotes the development of fatigue cracks. The coupling effects of three factors significantly reduces the flexural fatigue life of concrete, and the more the number of freeze-thaw cycles, the more significant the adverse effects on the flexural fatigue life of concrete. The addition of nano-particles (The cement in concrete is replaced by the same content of nano-particles) can improve the adverse effects of freeze-thaw cycles on the flexural fatigue life of concrete, and enhance the flexural fatigue life of concrete. When the amount of nano-particles is optimal, the fatigue life of NC10 and NS20 is increased by 47.6% and 52.3% respectively. The Cl− erosion resistance of concrete increases firstly and then decreases with the increasing amount of nano-particles. The free Cl− content of the compression zone in NC10 and NS20 can be reduced by 22.4% and 24.2% respectively, and the free Cl− content of the tensile zone in NC10 and NS20 can be reduced by 16.6% and 20% respectively. Under the coupling effects of three factors, with the continues erosion of Cl−, the Ca/Si value and the atomic percentage of Ca in interface transition zone (ITZ) of concrete gradually are decreased, which makes the decreased extent of C–S–H gel and Ca(OH)2 in concrete. The addition of nano-particles can reduce the decrease extent of Ca atom percentage in ITZ, reduce the decomposition of C–S–H gel and Ca(OH)2, and improve the fatigue life and Cl− erosion resistance of concrete.

Analysis of Effectiveness of Combined Surface Treatment Methods for Structural Parts with Holes to Enhance Their Fatigue Life

The typical and most widespread stress concentrators in the lower wing panels of aircraft are the drain holes located on the stringer vertical ribs. These are prime sources for the initiation and development of fatigue cracks, which lead to early failure of the wing structure. Therefore, improving fatigue life in these critical areas is one of the significant issues for research. Two combined methods of surface plastic treatment in the location around drain holes are discussed in this paper. Using the finite element method and ANSYS software, we created a finite element model and obtained nonlinear solution results in the case of tension in a plate with three holes. In addition, the development of residual stress due to the surface plastic treatment of the hole-adjacent areas was taken into account. In this paper, it is shown that after surface treatment of the corresponding areas of the holes, residual stress, which exceeds the yield stress for the plate material, is induced. When combined with alternative tensile stress, these reduce the amplitude of the local stresses, thus increasing the number of stress cycles before failure. The benefits of this technology were confirmed by fatigue test results, which include the fatigue failure types of the plates. Graphs showing the impact of applicable surface treatment combined methods on the number of cycles to failure were also plotted.

In-Motion Railcar Wheel Inspection using Magnetostrictive EMATs

Due to cyclic mechanical loading, railcar wheels are subject to the development of internal fatigue cracks in the rim underneath the tread surface. Off-line inspections are extremely laborious and require extended out-of-service time, and most existing in-line inspection systems that use conventional ultrasonics or electromagnetic acoustic transducer (EMAT) techniques have several drawbacks that limit their full-scale deployment in service. This paper discusses the work performed on the initial research and development of a proof-of-concept novel magnetostrictive EMAT sensor for in-motion railcar wheel inspection. Wheelsets with known internal discontinuities and a 3.7 m long panelized track were used to demonstrate the feasibility of the developed approach and methods. The results obtained from these tests have shown that the magnetostrictive EMAT sensor that generates 5 mm wavelength shear horizontal waves detects both surface defects and internal fatigue cracks with an excellent signal-to-noise ratio. Different wavelengths can also be added to the sensors to enhance or complement the detection of fatigue cracks at different depths. A total of four or five sensors located at standard concrete crosstie spacing along each rail would be able to provide complete coverage on wheels ranging from 711 to 965 mm in diameter with ±90° wheel coverage per sensor, and a theoretical inspection speed of 56 kph can be achieved using this approach.

Fatigue fracture cross-sections after cyclic tests with a combination of cyclic bending and torsion of samples made of aluminum alloy 6060

The paper presents the results of fatigue tests of the 6060 aluminum alloy. The test material was taken from the profiles used for production of side windows and external doors of the passenger trains by the RAWAG company. The tests were carried out for cyclic loads with pure bending, pure torsion, and two combinations of bending and torsion. Fatigue tests were performed at zero mean values. Using scanning electron microscopy, a fractographic analysis was made, which is a supplementary basis for considerations about the mechanism of initiation and development of fatigue cracks. Based on the appearance of individual zones and the characteristics of cracks, a picture of the behavior of the material under specific conditions was obtained. Finally, the plastic property of fatigue cracks was indicated. The work demonstrates the influence of aluminum alloy processing on the fatigue properties of this alloy during operation in order to obtain maximum reliability and safety of railway transport.

Detection of cracks in aircraft structures using digital image processing technology

Full-scale aircraft structural fatigue testing exposes structural weaknesses by simulating the use of the aircraft in service and monitoring the development and expansion of fatigue cracks to guide the optimisation of aircraft structural design, the determination of service life and the development of maintenance and repair programmes. If crack damage is not detected in time, the uncontrolled expansion of the crack may lead to structural damage and prolong the test cycle. Therefore, it is crucial to achieve accurate detection of early cracks in fatigue testing of aircraft structures. Digital image technology is a new technology supported by a number of technical and theoretical achievements. In practical application, it relies on the support of computer functions, by converting image information into two-dimensional digital signals, thus realising various operations. In this paper, digital image processing techniques are used to deepen the backbone feature extraction network structure and improve the prediction scale of small targets, thus improving the performance of the model in terms of feature extraction and small defect detection. Experimental results show that the method can achieve accurate detection of small cracks, providing an effective technical approach for the automatic detection of cracks in aircraft structural fatigue tests. The technique of detecting cracks in aircraft structures using digital image processing also provides a new idea for research into improving aircraft endurance testing, which can be further developed with the aid of image technology.

Analysis of Survivability of Cast Railroad Parts under Operational Loading

A comparison of the patterns of development of fatigue cracks in the modeling of the operational loading process and the calculated pattern, according to the linear summation algorithm using the standard fatigue fracture kinetic diagram of the same material, is carried out. The material is the low-alloy steel type 20L. During the tests, the load on a curved railway track section was simulated. The parameters of the original fatigue fracture kinetic diagram of material were corrected to adapt it to the calculation under irregular loading of this type.

The Influence of Repeated Heat Treatments on The Propagation of Fatigue Cracking of Medium Carburized Steel

The issue of metal fatigue emerged as one of the major issues in a variety of engineering designs, and the design engineers were forced to take metals' fatigue resistance into account. In this paper, multiple quenching mediums and varied heat treatments were utilized to examine the effects of various heat treatments on the development of fatigue cracking in steel. The model that was carburized, quenched in distilled water and tempered before being quenched once more in distilled water and tempered a second time had the best outcomes, the fewest cycles needed to cause the model to fail, and a correlation between the rate of fatigue crack propagation and the length of the crack, according to the results. Additionally, the analytical findings demonstrated that this model, as opposed to models with fixed stress intensity factors, has a fatigue crack growth rate. The model that was carburized, quenched in coolant, then tempered and quenched again without performing the tempered appearance failed very rapidly. The high rate of the stress intensity factor with fatigue crack propagation is shown by the data analysis. The results show a reduction in the growth amount tendency of fatigue crack in the linear region mode-III.

Quantum Mechanical-Based Fracture Behavior of L-PBF/SLM Ti-6Al-4V in the Very High Cycle Fatigue Regime

Abstract This work predicts bulk elastic properties and solves the wave function probabilistically using the density functional theory and by fixing outcomes with instrumented indentation. Revised bulk properties may predict crack start and propagation. Author-scripted pre- and post-processing in Abaqus simulated crack spread. Ultrasonic fatigue simulations increased fatigue life because the fracture onset phase was longer. We demonstrate that fatigue strength relies on elastic modulus because they are correlated. The verified results do not depend on any experimental evidence. Machine systems and scanning technologies have boosted the usage of selective laser-melted materials, leading to virtually full-density products. Microstructure and porosity from powder melting generate inconsistent mechanical performance under cyclic load. The extended finite element method was used to simulate crack propagation over an arbitrary fracture path to analyze fatigue crack development in additively generated fatigue specimens. Using fracture energy rate curves, loading level and testing frequency were evaluated on fatigue life. Micro computerized tomography (µ-CT) scans provide two-dimensional angular pictures. Several methods minimize faces and vertices. Open-source software was utilized to construct finite element models using µ-CT projections and to separate the cylindrical shell from internal pores. Crack propagation rate curves were used to investigate the impacts of loading level and testing frequency.

Use of Logarithmic Decrement of Oscillation Damping for Prediction of the Aviation Structures Service Life

Problem of predicting the residual service life of airplanes and helicopters is highly relevant for flight safety. In this paper, on the basis of the conducted research on the change of mechanical characteristics during materials fatigue accumulation, it is proposed to control the service life by changing the dissipative characteristics. In case of fatigue damage, the accumulative logarithmic decrement of oscillation damping δ increases to the limit maximum value δm, which corresponds to the critical length of the main fatigue crack, which leads to failure. The limit value δm can be set depending on the amount of energy spent on the development of the main fatigue crack, taking into account the dangerous part of the consumed energy. With the accumulation of fatigue damage, the growth of logarithmic decrement occurs at the expense of energy expenditure for the growth of fatigue cracks and internal friction. This is taken into account by the coefficient α, which allows to allocate a dangerous part of the energy that goes into the development of a main fatigue crack. The problem of durability prediction consists of two stages. At first, it is needed to determine δm for the critical crack length. Then, based on the two values of logarithmic decrement at the corresponding load cycles, the number of cycles to failure – to the critical length of the crack – is predicted by the Peris formula

Исследование циклической трещиностойкости стали литых несущих деталей грузовых вагонов

Purpose: Carrying out complex experimental studies of cyclic crack resistance of molten steel which is used for load-bearing parts of freight wagon running systems with kinetic diagram building for fatigue failure. Methods: Method of mechanical testing of molten steel samples under cyclic loading conditions was applied, the method makes it possible to obtain quantitative estimates of stuff ability to resist fatigue failure on the stage of fatigue crack development (testing on cyclic crack resistance). To study the surface of fatigue failure, relief micrographic analysis was used. To study molten steel elemental composition and the mechanisms of fatigue crack development, X-ray micro-spectral analysis was used on fatigue failure various stages. Results: The results of the research of cyclic crack resistance of 20 GL molten steel, which is used for load-bearing parts of freight cars, are presented. Fatigue failure kinetic diagram has been built, detailed micrographic analysis of fatigue failure surface has been carried out and elemental composition of non-metallic inclusions has been studied. Practical significance: Based on the research results, it is possible to assess the performance of 20 GL steel with cracks and to predict survivability. The results obtained make it possible to improve the methods of resource projection of molten bearing parts for freight wagon running systems in order to increase their operational reliability. The research results are used by enterprises - manufacturers of molten parts to control technology stability and to improve product quality.

Flexural fatigue behavior of butt-welded circular concrete-filled double skin steel tube (CFDST)：Experimental study and numerical modeling

Detailed understandings on the fatigue behavior of the concrete-filled double skin steel tubes (CFDSTs) under multiaxial stress states are essential to promote their applications in marine structures. A systematical investigation consisting both the experimental study and the according numerical modeling has been conducted. Physical tests were carried out to investigate the flexural fatigue behavior of the butt-welded hollow steel tubes (HSTs), concrete-filled steel tubes (CFSTs) and CFDSTs, in which the development of fatigue cracks and the fatigue life were captured. The feasibility of applying the existing S–N curves originally obtained from the HSTs to the constitutive steel tubes within the CFDSTs has been consequently verified. A two-stages simulation method was developed to analyze the full range development of fatigue cracks based on both the damage mechanics and the extended finite element method (XFEM). The influence of the multiaxial stress states on the fatigue behavior for the constitutive steel tubes was studied quantitatively, considering the offshore application scenarios where the steel tubes within the CFDSTs were subjected to larger external hydrostatic pressure or internal transmitted content pressure. The results show that the existence of the infilled concrete can effectively improve the fatigue behavior of the steel tubes. The life prediction models for both the fatigue crack initiation stage and propagation stage have been proposed, where the crack initiation life of the steel tube may reduce by 30% when its stress triaxiality increases from 0.36 to 0.48.

Regularities of plastic deformation development in the crack tip vicinity

When determining the service life of cyclically loaded metal structures at the stage of fatigue crack development, an important role is played by the accuracy of assessing the plastic deformation zone size at the crack tip formed by the tensile overload. Within this zone, after reducing the load to the initial level, the fatigue crack development slows down. Despite the large number of studies in this area, none of the proposed dependencies is currently fully confirmed by experimental results in determining the plasticity zone size. The aim of the work is to assess the size of the plastic deformation zone formed by a single tensile overload. In the work of the finite element method for central-notch specimens and compact tension specimens, an analysis of the stress-strain state in the crack top vicinity is performed. As a calculation, a flat and three-dimensional model was used. Calculations are performed in the Ansys 14.0. Data on the mechanical properties of steels were used: St20, VSt3sp, 09G2S, 15G2SF. With increasing load, the plastic zone size in front of the crack tip was estimated, in the process of reduction, the distribution and length of the fields of residual compressive stresses and the size of the cyclic plastic zone were recorded, the length of which was also determined experimentally using strain gauges with a base of 0.5 mm. To assess the plastic zone size formed by a single tensile overload, a dependence is proposed that takes into account the patterns of plastic deformation development in the vicinity of the fatigue crack tip, and the results of the calculation agree well with the experimental data given in the literature. The obtained expression makes it possible to predict with greater reliability the development of fatigue cracks at variable load amplitudes.

Multi-regime fatigue failure model based on damage theory

The prediction of a spatial fatigue crack development under arbitrary loading conditions is a complex problem. This paper introduces a new approach to predict crack initiation and propagation development based on damage theory. The fatigue degradation of the material within a physically small volume is described by the kinetic equation for damage function. The mechanical properties of the material (elastic moduli) depend on the damage function value. The uniform descriptions of the left and right branches of the full SN-curve allow the introduction of the general numerical procedure for fatigue ranges from HCF to VHCF. At the initial stage, the values of the damage function are calculated based on the elastic or elastic-plastic solution. The damage function is associated with two different mechanisms of fatigue damage accumulations. The first one is due to normal stress and the second one is due to shear. The contribution of each mechanism to damage function development is calculated simultaneously. As soon as the damage function gets the critical value the dominant mechanism is established. Therefore, the proposed multi regime model and numerical procedure are capable to predict crack initiation, spatial crack propagation and dominant crack opening mechanism at different stages of crack growth.

Metody obliczeń wytrzymałości zmęczeniowej części maszyn

Regardless of the operating conditions, a load acts on the parts of a machine in different directions. These loads in particular determine the required strength and resistance of parts and determine the study and selection of appropriate strength, resistance parameters for the parts. This can be determined by their impact on oilfield equipment and machine parts. Testing is done to determine the static flexibility, flow limit, tensile strength relative to flexibility, strength period limit, and plastic deformation coefficient. In some cases, when the limits of wear of machine parts are equal, elements with a larger coefficient of deformation are more convenient. These regularities should be used in those cases when it is possible to apply the methods of fracture mechanics or when there are direct experimental data on the development of fatigue cracks, which make it possible to carry out a probabilistic assessment of the durability of structural elements at the stage of crack growth and to substantiate the corresponding limitations on the service life of products. For the safety margins of machine parts, the starting points are as follows: longitudinal bending stress in the sleeve of a solid machine part made of a plastic material cannot damage the part. The length of the first crack can be taken to be equal to several millimetres, which is determined by the capabilities of the simplest means of observation, and by the fact that in some cases even a crack of such length can be critical from the point of view of a potential brittle fracture. In this regard, the fatigue resistance characteristics used in such a calculation should correspond to the point at which the first macroscopic crack appears.

Applications of bispectrum analysis to inspection of fatigue damage in quay cranes

The quay crane is a special mechanical equipment which can lift the container vertically and horizontally through intermittent circulation movement. Fatigue crack is one of the main kinds of damage in quay cranes. The generation and development of fatigue crack are invisible, which makes the identification of fatigue cracks a great challenge. From the dynamic point of view, fatigue cracks have nonlinear dynamic characteristics beyond the linear dynamic category. The traditional damage detection methods based on linear hypothesis are difficult to effectively recognize the nonlinear dynamic characteristics of fatigue cracks, so they cannot be effectively used for structural fatigue crack detection. In order to overcome the limitations of the existing linear damage detection methods, bispectrum analysis, a nonlinear dynamic analysis method, is introduced in this thesis. By drawing on the use of bispectrum analysis to describe the nonlinear dynamic characteristics of rotating structures, a fatigue crack detection method based on nonlinear dynamic characteristics of quay cranes is developed.

Fatigue damage assessment of complex railway turnout crossings via Peridynamics-based digital twin

Railway turnouts are essential in the train traffic route management for modern railways. Despite significant devotion to railway turnout research, one of their most common failures has not been thoroughly investigated, which is a fatigue over the turnout crossing nose. At the crossings, wheel-rail discontinuity imparts high-frequency high-magnitude forces, which are the source of fatigue failure over the crossing nose. In this study, a novel approach built on “Peridynamics” (PD) has been developed to obtain new insights into the fatigue cracks. A recent approach using “crack on mid-plane” has also been employed in this study to enhance the limited capability of Peridynamics. This paper is the world’s first to investigate fatigue failures over a crossing nose from fracture mechanics perspective. This paper also introduces a novel adaptive time-mapping method as an alternative to earlier time-mapping methods for fatigue models proposed in the open literature. The new model has been verified against both Finite Element Method and experimental data. It reveals that our new approach can simulate fatigue damage, particularly in mode I crack propagation. The study has provided important insights on the fatigue crack development, which is not possible before by existing Peridynamics fatigue model. The new approach on the basis of “adaptive time-mapping” and “crack on mid-plane” is demonstrated to be effective and efficient in PD simulations.