Small Punch Test Research Articles

Fracture resistance measurement in small punch test supported by optical monitoring device

Fracture resistance measurement in small punch test supported by optical monitoring device

Study on the effect of Si content on the compatibility of F/M steels with lead-bismuth eutectic using small punch testing

This study investigates the impact of silicon (Si) on the corrosion resistance and post-corrosion toughness of ferrite/martensitic (F/M) steels in a liquid lead-bismuth eutectic (LBE) environment. Corrosion tests were performed on HT-9 and EP-823 (1.17 wt.% Si) steels at 550 °C for 1000 h under oxygen-controlled conditions. The resulting oxide layer consisted of an outer magnetite layer, a spinel layer and an inner oxide zone (IOZ). A Si-rich oxide layer was identified within the spinel and IOZ layers of EP-823, which slowed the growth rate of the oxide layer, enhanced antioxidant performance, and inhibited dissolution corrosion by the LBE. Post-corrosion mechanical properties were evaluated using a small punch test. Results showed a significant reduction in HT-9’s toughness within 240 h of corrosion, while EP-823 exhibited increased brittleness after 500 h due to Si-promoted carbide and Laves phase precipitation, significantly reducing its toughness.

Small punch test size reduction to enable high flux irradiation

Screening and qualification of new nuclear materials with superior irradiation resistance requires expensive irradiation exposure and post-irradiation examination before consideration into industrial nuclear structural components. The development of miniaturized test methods is needed for enhanced cost/time efficient testing, while enabling comparative and robust material property estimation in a timely and high throughput manner. The Small Punch Test (SPT) is drawing much interest, especially since the publication of an European standard. Motivated by this standard, a new SP test sample geometry is proposed in order to reduce the material volume to be tested, hences increasing the number of samples that can be introduced in an irradiation rig is proposed. The modified sample diameter has been reduced from 8 to 5.35 mm. The qualification of this new design is described here together with a detailed description of the SPT setup modification as compared to the reference setup of the EN standard. Finite element analyses and a series of experiments have been conducted using both standard and reduced size SP samples to demonstrate that the modified test gives estimates of the basic mechanical properties with the same magnitude of error and validates the modified sample geometry for usage in irradiated material testing.

A Study on the influence of indenter shape for small punch test of non-metallic materials

A Study on the influence of indenter shape for small punch test of non-metallic materials

Small Punch Test to Estimate the Threshold Stress in Aggressive Environments by Incremental Step Loading

The present work is a relevant advance in the validation of the incremental step loading technique (ASTM F1624 standard) when applied to Small Punch tests (SPT) for the threshold load determination of medium- and high-strength steels in aggressive environments, as a novel alternative to conventional time-consuming tests under constant load. It completes previous works by the authors on this topic, extending a methodology to estimate the threshold stress from SPT tests in aggressive environments, covering the whole range of hardness marked by ASTM F1624 as the main goal. This is achieved by calibrating a model of the material’s hardness by the use of a coefficient in function of it. For this purpose, four medium- and high-strength steels of 33, 35, 50 and 60 HRC (Hardness Rockwell C) are exposed to three different cathodic polarization hydrogen embrittlement environments of 1, 5 and 10 mA/cm2 in 1N H2SO4 acid electrolyte connected to a platinum anode. Threshold stresses in these circumstances are obtained by uniaxial specimens following ASTM F1624 and compared to their homologous threshold loads obtained by Small Punch tests according to the authors’ original methodology proposal. Finally, the aforementioned model, consisting of a correlation based on composing an elastic and a plastic part, is calibrated for a hardness ranging 33–60 HRC, this being the main original contribution of this work; the elastic part is dependent just on the elastic-to-plastic transition SPT load, while the plastic part is ruled by a material hardness-dependent coefficient. This technique supposes an advance in engineering tools, due to its applicability in situations of material shortage, such as in-service components, welded joints, local areas, complex geometries, small thicknesses, etc., often present in aerospace, automotive or oil–gas, among others.

Development of the small punch fatigue test method based on the finite element method

The Small Punch Test (SPT) is a method of evaluating the mechanical properties of metallic materials that overcomes the limitations of the Uniaxial Test (UT), a traditional method of testing. Unlike UT, which provides strain data for each stress, SPT provides displacement data for each load. Therefore, SPT must be converted to UT to evaluate the mechanical properties of materials. However, SPT and UT employ disparate loading mechanisms. The difficulty in converting SPT to UT, which stems from the disparate loading mechanisms, has thus far limited SPT to mechanical property evaluation areas such as tensile and creep. This paper, therefore, aims to extend SPT to the fatigue domain, which is currently limited to the tensile and creep domains. The fatigue properties of metallic materials were evaluated based on the Finite Element Method (FEM) for the Small Punch Fatigue Test (SPFT). Moreover, the fatigue properties derived from the FEM for SPFT were converted to Uniaxial Fatigue Test (UFT) by employing the equivalent equation. Finally, an S-N curve was constructed based on SPFT and was validated by comparison with the same curve constructed based on UFT.

Determination of the Gurson-Tvergaard-Needleman damage model parameters for simulating small punch tests of heat-resistant alloys

The small punch (SP) test is utilized to assess the mechanical characteristics and damage progression of heat-resistant alloys. The inverse finite element analysis method incorporating SP tests is a parameter identification method based on adjusting the accuracy of the simulated load-displacement curves. In this paper, the elastoplastic parameters of the Hollomon model and the damage parameters of the Gurson-Tvergaard-Needleman (GTN) model are determined based on the undamaged and damaged stages of the load-displacement curves, respectively. The whole stress-strain curves of the tested materials are then built using the results of finite element simulations of the tensile specimens of ZG15Cr2Mo1, P91, 316H, and Hastelloy X at room and elevated temperatures. Comparison with uniaxial tensile tests indicates that the simulated stress-strain curves closely resemble the experimental data from the tensile testing. In addition, the simulated damage evolution characteristics of the SP specimens are consistent with the mechanical model based on the actual deformation behavior. It is possible to comprehend the damage evolution process by analyzing the SP specimens’ stress and strain change characteristics.

Size Effect on the Ductile Fracture of the Aluminium Alloy 2024-T351

BackgroundReliably calibrated criteria are needed for an accurate prediction of fracture of various components. However, there is not always a sufficient amount of material available. Therefore, miniature testing provides an alternative that is researched together with the following calibration of the ductile fracture criteria and investigating the size effect.ObjectiveThe aim is to design miniature testing equipment and specimens for tensile testing, which covers various stress states. This is supplemented by the small punch test, which has the same specimen thickness, taken from the literature to broaden the portfolio for calibration. The second part deals with conducting the finite element analysis, which provided a basis for the calibration of the phenomenological ductile fracture criterion applicable to crack-free bodies to indicate the crack initiation.MethodsThe steel frame to test thin specimens is designed with optical measurement of deformations. The finite element method is used, within Abaqus and user subroutines, to simulate the tests to obtain the variables needed for the calibration. In addition, the calibration of the criterion using machine learning is explored.ResultsThe feasibility of the proposed experimental program is tested on the aluminium alloy 2024-T351. Moreover, the numerical simulations, which showed a good match with experiments in terms of force responses, adds to the knowledge of modelling in the scope of continuum damage mechanics.ConclusionsThe presented results provide a material basis for the aluminium alloy studied on a lower scale, while they broaden the testing possibilities and analyses the calibration strategies for the best failure predictability possible.

Research on influence factors of small punch test to evaluate the mechanical properties of gradient nanostructured material

Abstract The influence factors of small punch test (SPT) were investigated to evaluate the mechanical properties of gradient nanostructured (GNS) materials. The gradient nanostructure was prepared on the top layer of S30408 austenitic stainless steel by ultrasonic impact treatment (UIT). The mechanical properties of the GNS material were obtained using SPT and correlated with those obtained by standard tensile tests. The results indicate that, when the specimen thickness is 0.5 mm, the sphere diameter is 2.4 mm, the punch velocity is 0.5 mm min−1, and the gradient nano-grained layer is placed face-on in the mold, the GNS material exhibits better plastic deformability. The SPT specimen achieves better bearing capacity, and the mechanical properties of the GNS material obtained by SPT are more accurate. The yield strength and tensile strength of the GNS material were also evaluated by analytical and empirical methods in SPT. The error is approximately 10% compared with the standard tensile test results, which is within the allowable range.

Development of a novel approach to correlate small punch fatigue with uniaxial ratcheting fatigue

The miniaturization of fatigue specimens has seen significant advancements, realized either by scaling down conventional specimens while preserving their geometry or by experimenting with novel specimen shapes and loading configurations. In this study, the small punch test (SPT) technique, which is well-established for estimating tensile, creep, and ductile-to-brittle transition temperature (DBTT), is employed to predict the cyclic deformation behaviour of SS 316LN and modified 9Cr-1Mo (P91) steels. The small punch fatigue (SPF) experiments demonstrated continuous displacement accumulation, similar to strain accumulation in ratcheting. The study evaluates the influence of various load parameters, such as amplitude and mean load, on SPF outcomes and compares these to the effects of stress amplitude and mean stress on ratcheting results. The differences in deformation behaviour between ratcheting and small punch fatigue and the effect of biaxiality in SP configuration life is analysed. Finally, to establish a correlation between SPF and ratcheting results, the three life prediction models (Gerber, Goodman, and Smith-Watson-Topper) are examined and a new correlation is proposed by introducing a novel damage parameter.

Creep properties of heat-resistant ultrafine-grained Al (HITEMAL©) determined by small punch testing

The creep properties of thermally stable ultrafine-grained Al metal matrix composite strengthened and stabilized by continuous in situ amorphous Al2O3 network (named HITEMAL©) prepared by powder metallurgy (PM) were tested by small punch creep testing (SPCT) in the temperature range from 573 to 673 K. The experimental SPCT results were correlated and compared with the results obtained by conventional tensile creep testing. The mutual correlation between tensile and SPCT creep results based on the transition stress was proposed and used to correctly interpret the measured SPCT data. The creep behaviour of HITEMAL© is characterized by the high values of apparent stress exponents and by the presence of transition stress at which the apparent stress exponents significantly changed. The SPCT discs fractured by the radial cracks at low values of deflection with only limited creep deformation highly localized in the vicinity of the fracture surfaces. The detailed analysis of fractured SPCT discs by scanning electron microscopy showed ductile dimpled fracture surfaces with the presence of unusual high filament-like tearing edges. The comparison of obtained results with other PM Al-based alloys and composites confirmed a significantly higher creep performance of HITEMAL© at used testing conditions.

Application of Digital Image Correlation to Small Punch Test for Determination of Stress–Strain Properties

The analysis of the small punch test is based on the force on the moving punch and the deflection data acquired at a single point of the specimen bottom. However, the spatial distribution of stress and strain at any given instant is non-uniform and its variations with increase in punch penetration are quite complex. In this work, the digital image correlation (DIC) technique is integrated with small punch test for in-situ full field strain measurement in the bottom surface of the specimen. The DIC results reveal that with the progression of deformation, the peak equivalent plastic strain at the bottom surface shifts from the center of the specimen to a characteristic radial location, where the strain rapidly builds up and concentrates leading to instability and cracking. Combining DIC-based strain results with finite element model-based stress estimation at the characteristic radial location, a methodology for determining the stress–strain curve from small punch test is formulated and the outcomes are compared with tensile test results for four different metallic alloys.

Small Punch Testing of a Ti6Al4V Titanium Alloy and Simulations under Different Stress Triaxialities.

The mechanical properties of local materials subjected to various stress triaxialities were investigated via self-designed small punch tests and corresponding simulations, which were tailored to the geometry and notch forms of the samples. The finite element model was developed on the basis of the actual test method. After verifying the accuracy of the simulation, the stress, strain, and void volume fraction distributions of the Ti6Al4V titanium alloy under different stress states were compared and analyzed. The results indicate that the mechanical properties of the local material significantly differ during downward pressing depending on the geometric shape. A three-dimensional tensile stress state was observed in the center area, where the void volume fraction was greater than the fracture void volume fraction. The fracture morphology of the samples further confirmed the presence of different stress states. Specifically, the fracture morphology of the globular head samples (with or without U-shaped notches) predominantly featured dimples. Modifying the specimen's geometry effectively increased stress triaxiality, facilitating the determination of the material's constitutive relationship under varying stress states.

Comments on standard EN-10371 and proposals for standard follow up

The small punch test technique was developed in the USA in the 1980 s, followed shortly by Japan and introduced to Europe in the 1990 s. CEN organized Workshop 21 to summarize more than ten years of research results and formulate the first technical guidelines CWA 15627. The specification work for European standard started in 2015 and the first European standard EN-10371 was published in 2022. The EN-10371 standardized the specimen size and test apparatus. It also specifies the test procedure and characteristic parameters for small punch test (SP) and small punch creep test (SPC). Nine annexes allows estimation of the values normally obtained using classical standard size uniaxial or fracture mechanics specimens. In order to make the standard perfect and usable, the standard working group proposed a five year “standard follow up” project in 2019. Responding to the proposed project, authors carefully re-examined the specification, and found some shortcomings in the standard. Proposals are put forward to improve the current methodology and extend the standard scope to include the latest development.

Analysis, Assessment, and Mitigation of Stress Corrosion Cracking in Austenitic Stainless Steels in the Oil and Gas Sector: A Review

This comprehensive review examines the phenomena of stress corrosion cracking (SCC) and chloride-induced stress corrosion cracking (Cl-SCC) in materials commonly used in the oil and gas industry, with a focus on austenitic stainless steels. The study reveals that SCC initiation can occur at temperatures as low as 20 °C, while Cl-SCC propagation rates significantly increase above 60 °C, reaching up to 0.1 mm/day in environments with high chloride concentrations. Experimental methods such as Slow Strain Rate Tests (SSRTs), Small Punch Tests (SPTs), and Constant-Load Tests (CLTs) were employed to quantify the impacts of temperature, chloride concentration, and pH on SCC susceptibility. The results highlight the critical role of these factors in determining the susceptibility of materials to SCC. The review emphasizes the importance of implementing various mitigation strategies to prevent SCC, including the use of corrosion-resistant alloys, protective coatings, cathodic protection, and corrosion inhibitors. Additionally, regular monitoring using advanced sensor technologies capable of detecting early signs of SCC is crucial for preventing the onset of SCC. The study concludes with practical recommendations for enhancing infrastructure resilience through meticulous material selection, comprehensive environmental monitoring, and proactive maintenance strategies, aimed at safeguarding operational integrity and ensuring environmental compliance. The review underscores the significance of considering the interplay between mechanical stresses and corrosive environments in the selection and application of materials in the oil and gas industry. Low pH levels and high temperatures facilitate the rapid progression of SCC, with experimental results indicating that stainless steel forms passive films with more defects under these conditions, reducing corrosion resistance. This interplay highlights the need for a comprehensive understanding of the complex interactions between materials, environments, and mechanical stresses to ensure the long-term integrity of critical infrastructure.

Using Small Punch Test to Investigate the Mechanical Properties of X42 Exposed to Gaseous Hydrogen: Effect of Pressure, Pre-charge Time, Punch Velocity and Oxygen Content

Using Small Punch Test to Investigate the Mechanical Properties of X42 Exposed to Gaseous Hydrogen: Effect of Pressure, Pre-charge Time, Punch Velocity and Oxygen Content

Prediction of fracture behavior during the small punch test for aluminum alloy 6061

The aim of this work is to investigate fracture mechanical characteristic of aluminum alloy 6061 by the small punch test in low range of deformation rate. The results of the force-displacement of the puncher curve and scanning electron microscope observation of fracture surface of deformed specimen are used to discuss fracture toughness of the material. The obtained results show that the influence of the displacement rate on the force - displacement of the puncher cannot be clearly seen. The mechanism of fracture properties of aluminum alloy 6061 is quite complicated and there is a large difference between the fracture surface of the top side which contacts with the punch head and the fracture surface of the bottom side. The bottom side shows not only crack in the direction perpendicular to the applied external force but also crack along the direction of the crack ring. The local ductile fracture might dominate to induce the initial crack due to shear stress. Then, the crack spreads via the direction perpendicular to the applied external force as well as along the direction of the crack ring without any dimples. Meanwhile, tensile stress plays an important role in breaking the specimen in half.

Estimation of Local Mechanical Properties by Small Punch Test in Welded Joints of Maraging C250 Steel

Estimation of Local Mechanical Properties by Small Punch Test in Welded Joints of Maraging C250 Steel

Optimization of Step Times for ASTM F1624 Methodology Applied to Small Punch Tests in Aggressive Environments

Threshold stress in aggressive environments is usually determined by tests under constant load, which are very time-consuming, so the incremental loading technique published in the ASTM F1624 standard was created to solve this issue. This approach has been recently applied to Small Punch tests, but it requires an optimization of the incremental step times, which is carried out in this work. Three medium- and high-strength quenched and tempered steels of 35, 50 and 60 HRC are exposed to three different cathodic polarization environments of 1, 5 and 10 mA/cm2 in 1N H2SO4 acid electrolyte with a Platinum anode, studying in each case three different step durations of one-quarter, one-sixth and one-eighth of the ones indicated in ASTM F1624. Optimal step times for Small Punch tests are derived from this work as one-sixth of the ones recommended in ASTM F1624 for tensile specimens, which are 20 min and 40 min for steps 1–10 and 11–20, respectively, in the case of 33 ≤ HRC < 45 steels, 10 min and 20 min for steps 1–10, 11–20 in the case of 45 ≤ HRC < 55 steels, and 10 min for steps 1–20 in the case of HRC ≥ 55 steels.

Inconel 718 Hybrid Laser-Based Directed Energy Deposition and Wrought Component Characterization through Small Punch Tests

The combination of wrought materials and laser-based directed energy deposition (DED-LB) is being increasingly used for manufacturing new and repairing old or damaged components in several industries. Aerospace components made of Inconel 718 featuring small-thickness DED-LB buildups are a remarkable example of such a combination due to the high added value it brings. Despite that these are usually critical components, the miniature testing methods to assess the local mechanical properties in the buildup area are not fully developed. This work contributes to this miniature testing development with an improvement of the small punch testing (SPT) technique for measuring the mechanical properties of the weld line between the DED-LB and the wrought substrate. A new criterion for weld line positioning in the SPT specimens is proposed and applied on samples of hybrid wrought/DED-LB Inconel 718. The results of positioning the weld line at the necking site of the SPT specimen show that the proposed approach is valid for assessing the properties of the transition zone between the wrought and additive states. For the specific conditions tested and taking the wrought material as a reference, the strength of the Inconel 718 drops 10% in the weld line and 20% in the buildup.