Number Of Loading Cycles Research Articles

Influence of corrosion fatigue on the stress gradient effect of the aluminium alloy EN AW-6082 T6

This study investigates the influence of corrosion fatigue on the fatigue strength of the aluminium alloy EN AW-6082 T6 with regard to the stress gradient. The experimental design involves varying loading conditions and specimen geometries to facilitate testing under three distinct stress gradients: tension/compression (0mm-1), rotary bending (0.2mm-1), notched rotary bending (5.3mm-1). Reference constant loading tests in air as well as continuously irrigated corrosion fatigue tests in a 5wt% NaCl-solution are conducted with a constant stress ratio of R =−1. The results reveal a substantial reduction in fatigue strength due to corrosion fatigue across all three stress gradients. The slope of the S-N curves drops by a factor of at least two and no second slope of the S-N curves is found within the tested load cycle range (up to 107). The study demonstrates a significant increase in the support factor for tests conducted in the corrosive environment. This discrepancy becomes more pronounced towards higher stress gradients and lower load cycle numbers. The application of the support factor derived from tests in a non-corrosive atmosphere is shown to be conservative, emphasizing the significance of accounting for corrosion effects in assessing fatigue behaviour.

An interlaminar fatigue damage model based on property degradation of carbon fiber-reinforced polymer composites

Interface delamination is a significant damage mechanism in fiber-reinforced polymer (FRP) laminated composites caused by interlaminar normal and shear stresses. This is due to the low interlaminar properties including interface stiffness and strength that continuously degrade to cause fatigue crack nucleation and growth. In this respect, an interlaminar fatigue damage model is proposed to accurately address the reliability aspect of the FRP composite materials and structures. The model considers a damage process that consists of two stages: (1) fatigue damage evolution due to interlaminar properties degradation to the onset of crack nucleation. A cyclic cohesive zone model with a bilinear softening behavior is introduced along with the fatigue life model to capture the mean stress effect of the interface. This is followed by (2) the crack nucleation process leading to the physical separation/debonding of the interface material point, as governed by the cycle-dependent fracture energy dissipation. The mechanical prediction of the interlaminar fatigue damage process is illustrated through finite element simulation of a mixed-mode flexural test of a carbon fiber-reinforced polymer (CFRP) composite beam subjected to fatigue loading. The results indicate that the interlaminar normal and shear crack opening displacement increases exponentially with the larger number of load cycles. In addition, the high-stress gradient is limited to the interface crack front zone with the normal and shear stress peaks at 69.2 and 16.5 % of the respective interlaminar strength. Moreover, controlled interlaminar crack growth is initially foreseen at 7.0 × 10-6 mm/cycle, followed by an abrupt crack “jump” at 287,000 load cycles.

A quantitative residual stiffness model for carbon fiber reinforced polymer tendons

AbstractIn this study, tension‐tension fatigue tests were conducted to investigate the residual stiffness degradation of carbon fiber‐reinforced polymer (CFRP) tendons. Different stress levels were used in the tests, and measurements of residual stiffness and the number of loading cycles were taken. Based on experimental data for CFRP tendons, a quantitative residual stiffness model was developed by modifying Yao's model. This model is applicable to various stress levels. To assess its accuracy and applicability, the predicted results of this model were compared with those of cited models from other researchers. The findings revealed a three‐stage degradation of residual stiffness in CFRP tendons under different stress levels. Furthermore, it was observed that the proportion of fatigue life accounted for by Stage III decreased with smaller stress ranges, while the proportion accounted for by Stage II increased. The proposed quantitative residual stiffness model was verified using both experimental and cited data.

Compressive residual strength of the pultruded glass-fiber composite after tension-compression fatigue

We experimentally determined the decrease of residual compressive strength of the pultruded glass-fiber laminate after tension-compression cyclic loading. The adapted Arcan rig was used for tension-compression fatigue tests. The cyclic load was applied with the critical stress ratio R=−0.87. The residual compressive strength was determined after applying the predefined number of loading cycles with the stress amplitudes of 242 MPa and 173 MPa. The results indicated that the residual compressive strength was reduced about 20% at 77% of fatigue life under the stress amplitude of 242 MPa and at 83% of fatigue life under the stress amplitude of 173 MPa. The microstructural analysis showed that the crack growth path and failure mode depend on the stress amplitude.

Experimental Study of the Mechanical Properties of Full-Scale Rubber Bearings at 23 °C, 0 °C, and -20 °C.

In this study, the effects of ambient temperature on the horizontal mechanical performance of isolated rubber bearings were investigated using high-speed reciprocating loading methods. A comprehensive series of 54 experimental trials are performed on the full-scale (900 mm-diameter) isolation rubber bearings, encompassing a range of temperatures (-20 °C, 0 °C, and 23 °C), shear pressures (50%, 100%, and 250%), and frequencies (0.20 Hz, 0.25 Hz, and 0.30 Hz). Because the compression-shear tests were conducted at high velocities and pressures (specifically, vertical compressive stress of 15 MPa), the equipment used in these tests was capable of generating substantial inertial and frictional forces. Appropriate correction methodologies for the precise determination of mechanical performance metrics for bearings are presented. Then, a comprehensive investigation of the effects of various loading conditions on the characteristic strength, post-yield stiffness, horizontal equivalent stiffness, and equivalent damping ratio of LRB900 (lead-core rubber bearings 900 mm-diameter) and LNR900 (linear natural rubber bearings 900 mm-diameter) is conducted. The empirical results show a discernible relationship between these characteristics and ambient temperature as the number of loading cycles increases, except for the equivalent damping ratio. Finally, empirical fitting formulations incorporating the influence of ambient temperature are presented for each performance indicator. These formulas are intended to assist designers in performing seismic design analyses by allowing them to take into consideration the effects of ambient temperature comprehensively.

An experimental study on the bending fatigue behavior of concrete beams by a proposed machine

Cyclic loading can induce brittle fractures at stress levels below the strength threshold, prompting extensive experimental and numerical investigations into the fatigue characteristics of various elements. This study introduces a purpose-built machine designed to empirically explore the fatigue behavior of concrete beams. The proposed machine employs a rotational beam system with a consistent load applied to the beam’s end. By placing a single point on the rotating beam, cyclic flexural moments are generated, inducing maximum tensile stresses at the support. This machine enables continuous long-term testing, adjustment of load amplitude and loading frequency, and tracking the number of cyclic loads until specimen failure. The stress-number cyclic loading test is performed on diverse samples of both reinforced and unreinforced concrete beams. Furthermore, the study assesses the impact of loading frequency on fatigue behavior. The findings validate existing relationships proposed for the durability limit in terms of tensile strength.

Rolling–sliding wear and damage behaviors of 304L stainless steel laser cladding on a damaged wheel tread under high ambient temperature conditions

To prolong the service life of wheels, damage to wheel tread was repaired locally by laser cladding. However, wheels in service in open environments are subject to high ambient temperatures, especially in the southern coastal areas of China, and the repair effects have not yet been verified. Therefore, in this study, laser cladding was used to clad 304L stainless steel powder on a damaged wheel tread to implement local repair of the damaged wheel. A friction and wear test was carried out using a twin-disc tester with a climate chamber to explore the influence of different loading cycles on the wear and damage behavior of repaired wheels at a high ambient temperature. The results showed that with increasing number of loading cycles, the friction coefficient between the wheel and rail gradually stabilized at 0.30–0.35, and the wear rate exhibited a similar trend. After 1 × 105 r, the surface hardness and plastic deformation thickness remained stable. The damage form changes from small spalling pits and nonpropagating microcracks to bulk material spalling and parallel cracks with large-angle branches. A high ambient temperature had little effect on the metallurgical bonding between the cladding layer and the wheel substrate, and no crack damage occurred.

Evaluation of the fatigue resistance of butt-welded joints in towers of wind turbines — a comparison of experimental studies with small scale and component tests as well as numerical based approaches with local concepts

Wind turbines must endure a high number of load cycles during their service lifetime. Therefore, the fatigue strength verification plays an important role. Butt-welded joints are one of the most common structural details in the tower structure of wind turbines. In general, the nominal stress method is used for their fatigue verification. The Eurocode 3 part 1–9 is the current design standard for this field of application and defines the fatigue resistance by pre-defined FAT-classes. This paper presents recent results of fatigue tests on small-scaled specimens and large components with transverse butt welds to discuss the validity of the FAT-class. In addition, results from numerical simulations for the verification with the effective notch stress and the crack propagation approach are used for comparison. For this purpose, macroscopic measurements of the weld seam geometry and a 3D scan were used for a realistic consideration of the notch effect in the simulation. Based on the consistency between the numerical results and the fatigue tests, the influence of the seam geometry on the fatigue resistance was worked out. Furthermore, a prediction of the fatigue strength of butt-welded joints with plate thicknesses up to 80 mm was carried out.

Influence of carbon layer hardness characteristics on RCF performance of carburized bearing steel and optimization of heat treatment process

Being a pivotal element within high-speed train transmission systems, the mechanical attributes of bearings are of great significance to ensure the quality and safety of train operation. In this study, the rolling contact fatigue performance of bearing materials was tested to investigate the effects of different carbon layer characteristics on the rolling contact fatigue behavior. Combined with the thickness of carburizing layer, the elastoplastic coupling model of rolling contact fatigue damage of G20CrNi2MoA carburizing bearing steel was established. The model revealed the relationship between the number of load cycles and the degree of subsequent material damage. The model was used to calculate and predict the loading frequency of G20CrNi2MoA carburized bearing steel with excellent fatigue characteristics, which was 2.02 × 108 times before spalling. In addition, the carburizing heat treatment process for bearings was optimized based on the hardness gradient curves obtained, which provided valuable insights for improving the actual production process.

Characterization of a NEG cartridge under high pressure conditions

The development of advanced sintered pumping elements based on the ZAO® alloy, characterized by a high affinity towards hydrogen and its isotopes, make Non Evaporable Getter (NEG) pumps particularly appealing for applications in fusion research, which typically deal with large fluxes of these gaseous species. NEG getters show high pumping speeds and capacity, excellent reliability with ability to withstand a high number of loading and unloading cycles without showing any type of failure, ease of integration within a complex system (such as a fusion reactor) because of their high specific properties and the simplicity of the mechanism that regulates its operation. These properties make NEG technology particularly suitable for the development of compact, efficient and easily scalable solutions, which are also very safe, since the release of absorbed hydrogen is prevented in the case of power outage or subsystem failures, as it can occur only by providing an adequate amount of heat to the getter material. This paper reports the results of an experimental campaign conducted on a new type of NEG pump, aimed to obtaining an accurate characterization in response to different operating conditions. Hydrogen pumping speed was investigated in a range of pressures of particular interest for the activities of the Divertor Tokamak Test facility (between 0.1 and 10 Pa). The influence of nitrogen absorption and getter material operating temperature on the pumping performances of the NEG pump were also examined. Finally, numerical simulations have been performed to estimate the nominal pumping speed of the NEG pump, that is, the one acting at the absorbing surface, stripped of the effects of the conductance of the paths from the pump NEG to the pressure gauges.

Design of Multi-Input Multi-Output Non-linear Model Predictive Control for Main Steam Temperature of Super Critical Boiler

Flexible operation of coal-fired power plants is becoming increasingly necessary for successful integration of large-scale renewable power generation into the power grid. The maximum ramp rate and the number of load cycles are generally limited by the thermal stress experienced by the boiler pressure parts, turbine metallurgy and creep and fatigue of critical thick-walled components Main steam temperature is a critical operating parameter that must be controlled within acceptable limits for safe operation. Main steam temperature deviation beyond acceptable limit has impact on boiler pressure parts and turbine material of construction due to creep and fatigue effect. Base load operating units do not require steep ramp rate and hence recommended ramping rates are kept low within the safe operating zone in comparison to the flexible operation of the units with wide range load change width. Thermal stresses are caused by the temperature changes inside the thick-walled components and turbine steam admission parameters. Hence, the quality of main steam temperature control plays a vital role in flexible operation of the coal fired units. Conventional cascaded PID temperature control loop architecture performs well at steady state condition within a limited variation of load change at low ramp rate but it acts slowly and performs poorly at transient operating conditions of flexible operation of the boiler turbine with wide range load variation and load cycle with high ramp rate and remains far from rated conditions. In this paper, a Multi-Input Multi-Output (MIMO) Non-linear Model Predictive Control (MPC) design for regulation of the main steam temperature of a Once-Through supercritical Boiler is proposed. The controller is based on a non-linear dynamic model which incorporates dynamics of the variables of interest. It has the capability to operate effectively across a wide load range while maintaining main steam temperature within acceptable limits. A notable advancement in this design of MPC is the incorporation of coal flow demand and feedwater flow demand as additional control inputs alongside primary and secondary spray flows. In simulation test cases, the MPC controller demonstrates satisfactory performance and computational efficiency.

Mitigating Reflection Cracking in Asphalt Concrete Overlays with ECC and Geotextile

The rehabilitation of deteriorated pavements using Asphalt Concrete (AC) overlays consistently confronts the reflection cracking challenge, where inherent cracks and joints from an existing pavement layer are mirrored in the new overlay. To address this issue, the current study evaluates the effectiveness of Engineered Cementitious Composite (ECC) and geotextile fabric as mitigation strategies. ECC, characterized by its tensile ductility, fracture resistance, and high deformation capacity, was examined in interlayer thicknesses of 7, 12, and 17 mm. Additionally, the impact of geotextile fabric positioning at the base and at 1/3 depth of the AC specimen was explored. Utilizing the Overlay Testing Machine (OTM) for evaluations, the research demonstrated that ECC17 significantly mitigated reflection cracking, showing a notable 764% increase in the number of load cycles to failure (Nf) compared to the Geotextile Base (GB) specimen. Against the Reference Specimen (RS), ECC17 exhibited a remarkable 1307% enhancement in Nf values, underscoring its effectiveness. Geotextile fabric, particularly at 1/3 depth, demonstrated notable resistance but was overshadowed by the performance of ECC interlayers. The results clearly indicate that ECC, especially ECC17, stands out as an effective solution for mitigating reflection cracking, including joints, in AC overlays.

A Two-Stage Mathematical Model for Evaluating the Modes of Forced Vibrations of an Aircraft Skin Element with the Use of Fiber-Optic Technologies

The purpose of research is development of a mathematical model of vibration vibrations of an aircraft skin element made in the form of a plate with a two-stage transformation "vibration load parameters – deformation of the plate - change in the wavelength of the optical signal" in order to take into account the number of loading cycles and their characteristics, accumulated fatigue deformation of the plate and its life before the critical state in order to optimize planned repairs and reducing the risks of unpredictable failures associated with fatigue phenomena in the skin material and supporting structures of the aircraft.Methods. The described mathematical model uses the parameters of a harmonic vibration signal as input data and includes a two-stage transformation, firstly, of the parameters of the vibration signal (frequency, amplitude) into the amplitude of the vibration vibrations of the aircraft skin element made in the form of a plate, secondly, the amplitude of the vibrations of the plate in question into a change in the wavelength of the optical signal, the presence of which is caused by the use of fiber-optic technologies that are promising for the construction of modern systems for monitoring and diagnostics of aircraft.Results. The proposed mathematical model allows calculating and analytical methods to estimate the amplitude of forced vibration vibrations of the aircraft skin element, which causes the absence of plate resource consumption due to the effects of loading cycles (there is only natural aging of the material), plate resource consumption in elastic deformation mode, accumulation of fatigue deformation of the sample. The method of evaluating the plate for the resonant effect is given, which indirectly affects the processes of designing the elements of the aircraft skin in terms of weight and size indicators, which largely determine the frequency of natural vibrations of the plate. The resulting deformation of the plate is expressed in a change in the wavelength of the light beam for detection and analysis by the control and diagnostic system of the aircraft, made on the basis of fiber-optic technologies.Conclusion. The proposed mathematical model is designed to assess the residual life of a specific element of the aircraft skin, involves subsequent software modeling to confirm the correctness or refinement of the resulting calculation algorithm.

Development of a Framework for Assessing Bitumen Fatigue Cracking Performance under Different Temperatures and Aging Conditions

A full understanding of bitumen fatigue cracking behavior is extremely important as this phenomenon has a considerable influence on bituminous pavement performance. The current framework for assessing this asphalt binder property is inconsistent in ranking bitumen fatigue performance in terms of the failure definition and damage characteristic curve (DCC) analysis. This study used four different types of asphalt binders: neat asphalt (NA), self-healing thermoplastic polyurethane (STP)-modified bitumen, self-healing poly (dimethyl siloxane) crosslinked with urea bond (IPA1w)-modified bitumen, and styrene–butadiene–styrene (SBS)-modified bitumen (SBSB). All the bitumens were subjected to short-term and long-term aging, and they were also tested by utilizing the linear amplitude sweep (LAS) test and the simplified viscoelastic continuum damage (S-VECD) model. LAS and S-VECD procedures were used to apply the newly proposed and current frameworks in order to analyze bitumen performance. The current framework showed that the bitumens that used a higher number of loading cycles (N) to reach their failure points (Nf) failed to exhibit greater fatigue performances in terms of DCC analysis. The developed framework (mainly based on the damage intensity [S] instead of N) was used to solve the inconsistency between the failure definition and DCC assessment in ranking bitumen performance. Additionally, the current framework (failure criterion) presented two R2 values below 0.1, but the developed framework (failure criterion) showed that all R2 values were greater than 0.9. The developed framework represents a turning point because, for the first time, this type of procedure is mainly being based on S instead of N. Although further tests are needed to confirm its efficiency, it eliminates the inconsistency between the failure definition and DCC assessment.

Combined Influence of Cyclic Loads and Corrosion on the Technical Condition of Metal Structures of Metro Escalators

This article examines the influence of loads, conventionally divided into static and cyclic ones, and of corrosion acting together on the structural elements of metal structures of metro escalators. The dynamics of corrosion processes are determined by the environment, the degree of influence of which, depending on the geographical location and based on seasonality, can vary from non-aggressive to highly aggressive. This, with simultaneous occurrence of deformations (a stressed state is created in the structure), can lead to fatigue failures. The state of the metal structure of the escalator in this case is the most important element, since the failure of almost any of its structural elements means a complete stop of the escalator.The prerequisites for corrosion fatigue for low carbon steels, as the main material in manufacture of metal structures for metro escalators, are also considered.The main objective of the study is to search for criteria for creating an experimental and computational method for determining the residual life of metal structures of metro escalators with a high degree of reliability. Identification and analysis of criteria for assessing the condition of metal structures was carried out by the authors using experimental research and survey methods, that resulted in a conclusion that the degree of degradation of the main characteristics and properties of metal structure elements is determined not only by the number of loading cycles, but also by the duration of exposure to an aggressive environment.

Empirical transfer functions for foam glass aggregates insulation used in flexible pavement layered systems

Pavement design in cold regions is challenging due to the difficult conditions of soils, humidity, and temperatures. Insulation layers have been identified as a suitable solution for these conditions. Due to their unique engineering properties, foam glass aggregates (FGAs) are a promising material for use as an insulating granular layer in pavement design. However, understanding their mechanical performance is critical for predicting long-term layer and pavement behavior. In this laboratory study, an empirical transfer function was developed using an environmental and heavy vehicle simulator and an experimental pavement built in an indoor test pit. The study aimed to determine the allowable number of load repetitions for an FGAs insulation layer and to develop an empirical transfer function that can be used as part of a mechanistic-empirical pavement design procedure. This article proposes a linear relationship between permanent deformation, the number of load cycles, and the equivalency factor between the effect of resilient strain, or vertical stress, and allowable damage. The proposed empirical transfer functions allow defining an allowable number of load repetitions for a characteristic resilient strain or vertical stress and an allowable damage. The allowable damage can be modulated with respect to road classification, and a damage value of 0 % to FGAs layer can be considered as a safety factor. The findings of this study provide valuable insights into the use of FGAs as an insulating granular layer in pavement design in cold regions.

Fatigue Behaviour of Medium Carbon Steel Assessed by the Barkhausen Noise Method

Abstract In this paper, an attempt to estimate the stage of the fatigue process using the Barkhausen noise method is studied. First, microstructural and static tensile tests were carried out and, subsequently, fatigue tests up to failure were conducted. After determination of the material behaviour in the assumed static and dynamic conditions, the interrupted fatigue tests were performed. Each specimen was stressed up to a different number of cycles corresponding to 10%, 30%, 50%, 70% and 90% of fatigue lifetime for the loading conditions considered. In the next step of the experimental programme, the specimens were subjected to the Barkhausen magnetic noise measurements. Various magnetic parameters coming from the rms Barkhausen noise envelopes were determined. The linear relationship betweenthe full-width at half-maximum (FWHM) of the Barkhausen noise envelope and the number of loading cycles to fracture was found. Specimens loaded up to a certain number of cycles were also subjected to a tensile test to assess an influence of fatigue on the fracture features.

Breakage behavior of corn kernels subjected to repeated loadings

Studying the breakage behavior of corn kernels subjected to repeated compressive events, including at low frequency and low strain rate, are important for the development of breakage models for prediction of kernel breakage in handling and processing machines. The main purpose of this study was to identify the breakage behavior and mechanism of weakening of corn kernels under repeated loadings as affected by their moisture content and kernel thickness. Corn kernels at four moisture content levels (8.20%, 11.95%, 16.00%, 20.02%) and in four thickness ranges were subjected to repeated compressive loading between two parallel steel plates in quasi-static regime at a constant loading rate of 2 mm/min (strain rates from 4.7 × 10−3 to 1.0 × 10−2). Conducted experiments allow to observe the different grain breakage patterns, identify the crack initiation and its development, describe the weakening of kernels by changes in the total specific energy, plastic and elastic deformation energies, and the number of loading cycles to break (breakage probability) the kernels. The results indicate that the breakage models describing the damage and weakening of grains in terms of changes in the total and strain energy or changes in the stiffness can be used for understanding the effect of moisture content and thickness on breakage of corn kernels.

Comparison of stiffness degradation in fatigue-loaded concrete cylinders and large-scale beams

Wind and wave loads subject the tower structures of wind turbines to bending stress. The resulting initial linear strain gradients in the tower cross-section cause fatigue-induced degradation of the concrete at the outer edge of the structures. As the number of load cycles increases, stresses are gradually redistributed to the inner cross-section of the structure consequently. Most of the test results documented in the literature were obtained from small-scale concrete specimens or small-scale components. In those cases, the stiffness and stress redistributions occurring in the real component can only be insufficiently derived, and possible scale effects cannot be taken into account. Besides, available test results for individual component tests are mostly only for load cycles up to 2⋅106. However, significantly lower load levels and thus higher number of load cycles are expected to occur in wind turbines compared to usual fatigue tests. To deal with this issue, extensive fatigue tests on small cylindrical specimens as well as large-scale beams in the very-high-cycle fatigue range are carried out in this work. The test results of both cylindrical and beam specimens show the typical three-phase stiffness curves known from the literature. These curves exhibit a disproportionate decrease at the beginning of the loading, followed by a constant decrease in stiffness, and finally, a greater decrease in stiffness shortly before failure. Moreover, the stiffness curves from the tests on both specimen types show good agreement. It can be concluded that the results from small cylindrical specimen tests can be transferred to large-scale structural components.

The influence of thermocyclic effects on the tribological properties of a carbon-carbon composite under braking conditions

The article considers the issues of the influence of repeated thermal shock on the frictional properties of a carbon-carbon composite material. For thermal loading, the heat-pulse method was applied, in which the energy of rotating masses is absorbed by a friction couple from samples of the material being studied. The change in the friction coefficient during braking is analyzed. Based on the results of repeated braking, conclusions are drawn about the resistance of the material to thermal cyclic behaviours. Particular attention is paid to the maximum temperature that occurs on friction surfaces and the temperature change during thermal loading. The dependence of the average friction coefficient in each test on the number of loading cycles was obtained. Based on the study, the number of thermal loads at which the frictional properties of the material are stable was established.