Test Specimen Orientation Research Articles

To predict the surface roughness of Black ABS component with variable parameters by applying the Taguchi method

The objective of this research is to find the best combination factor values for minimizing surface roughness in test materials using Fused Deposition Modelling (FDM), specifically targeting Acrylonitrile Butadiene Styrene (ABS). However, the research community has given less attention to the surface quality with adequate process parameters as a result. This research aims to close that gap. The Design of Experiment (DOE) method is utilized in this study to evaluate how particular characteristics such as orientation, infill density, and nozzle diameter impact the surface roughness of Ultimaker 2 + produced products. Taguchi Orthogonal array was used to produce the specimens to restrict the number of experiments and give different combinations of these three elements and their levels at each experiment. The outcomes were based on both practical and ANOVA data. The surface roughness tester of the contact type used in this experiment was Mitutoyo Surface SJ-210. And minimum surface roughness was achieved using less infill percentage, nozzle diameter, and horizontal orientation of test specimen.

Virtual pre-test analysis for optimization of multi-channel control strategies in direct field acoustic testing

Direct field acoustic excitation testing, or DFAX, is gaining the attention of the space industry as a reliable and flexible method to perform acoustic qualification tests of spacecrafts. The test aims at reproducing the sound conditions of the space launch using an array of high-powered loudspeakers placed around the test specimen. To achieve this end, advanced multi-input multi-output (MIMO) control strategies are employed to design the independent signals which drive the different speakers based on the responses acquired at the control locations over the test volume. Consequently, the performance and overall efficiency of the test campaign is then determined by a number of factors, among them stack configuration, test specimen orientation, number of speakers, control matrix and sensor location. To assist engineers in the design of such tests, this work proposes the use of numerical models to simulate the entire test set-up before the on-site campaign takes place. State-of-the-art vibro-acoustic solvers are employed to predict the pressure responses at all points in the test volume for various design choices, allowing test engineers to perform a virtual pre-test analysis based on numerical solutions to optimize their control strategy. The results included in this work illustrate the methodology followed to account for all the transfer functions of the electro-acoustic system as well as the validation of the levels of accuracy which can be achieved in a full-scale DFAX test via direct comparison with experimental measurements.

Estimation of Impact Toughness Transition Temperatures of As-Quenched Steels

High strength and sufficient toughness are key requirements for modern high-performance structural steels. In an attempt to develop a suitable estimation of impact toughness transition temperatures for as-quenched steels, we investigated the determiners of low-temperature toughness with a group of thermomechanically rolled direct-quenched steels with varying martensite contents. These were produced by altering chemical composition, finish rolling temperature and reduction below the non-recrystallization temperature, i.e. austenite pancaking, and characterised in terms of microstructural constituents, grain size distributions, texture and fractography. Provided the finish rolling temperature is high enough to avoid the formation of granular bainite on subsequent cooling, high levels of austenite pancaking yield the best combinations of low-temperature toughness and strength by effectively refining the size of the coarsest grains and randomizing the texture. While absolutely no direct correlation is found within as-quenched steels between the impact toughness transition temperatures and yield strength alone, T28J and T50 do closely follow a dynamic reference toughness, i.e. the opening stress intensity factor defined by yield strength and the size of the coarsest grains in the effective grain size distribution. This parameter reflects the transition temperatures – the lower the temperature, the lower the reference toughness needed to cause a local brittle fracture. Finally, we show that the impact toughness transition temperatures T28J and T50 of as-quenched steels can be accurately estimated, irrespective of the test specimen orientation, by utilizing just the dynamic reference toughness and the fraction of {100} cleavage planes within ± 15° of the specimen notch plane.

Strengthening mechanisms in directed energy deposited austenitic stainless steel

Microstructures and mechanical properties are evaluated in austenitic stainless steel structures fabricated by directed energy deposition (DED) considering the effects of applied loading orientation, build geometry, and distance from the deposition baseplate. Locations within an as-deposited build with different thermomechanical history display different yield strength, while those locations with similar history have approximately the same yield strength, regardless of test specimen orientation. Thermal expansion of deposited material near the baseplate is inhibited by the mechanical constraint imposed by the baseplate, promoting plastic deformation and producing a high density of dislocations. Concurrently, high initial cooling rates decrease away from the baseplate as the build is heated, causing an increased spacing of cellular solidification features. An analysis of strengthening mechanisms quantitatively established for the first time the important strengthening contribution of high dislocation densities in the materials (166–191 MPa) to yield strength that ranged from 438 to 553 MPa in the present DED fabricated structures. A newly adopted mechanistic relationship for microsegregation strengthening from the literature indicated an additional important contribution to strengthening (123–135 MPa) due to the cellular solidification features. These findings are corroborated by the measured evolution of microstructure and hardness caused by annealing the DED material. These results suggest that the mechanical properties of deposited austenitic stainless steels can be influenced by controlling thermomechanical history during the manufacturing process to alter the character of compositional microsegregation and the amount of induced plastic deformation.

Quasi-Static, Cyclic Fatigue and Fracture Behavior of Alloy Steel for Structural Applications: Influence of Orientation

Abstract In this paper, the results of a study aimed at understanding the extrinsic influence of test specimen orientation, with respect to a wrought alloy-steel plate, on the stress-controlled cyclic fatigue properties and fracture behavior of a structural steel is highlighted. The alloy steel chosen was ASTM A572 grade 50. Samples of this alloy steel, prepared from both the longitudinal and transverse orientations, were cyclically deformed over a range of maximum stress and the corresponding number of cycles to failure (NF) was recorded. The influence of test specimen orientation and intrinsic microstructural effects on cyclic fatigue life and fracture behavior are presented and discussed. Overall, the macroscopic fracture mode was essentially identical regardless of orientation of the test specimen with respect to the wrought plate. The microscopic mechanisms governing cyclic deformation, fatigue life, and final fracture behavior are presented in light of the mutually interactive influences of magnitude of applied stress, intrinsic microstructural effects, orientation of test specimen, and deformation characteristics of the key microstructural constituents.

The microstructure, tensile response and fracture behavior of a high-performance structural steel: influence of orientation

In this paper, the microstructure, hardness, tensile deformation and fracture behavior of a structural steel (ASTM A572-Grade 50) is presented and discussed. Specifically, the influence of test specimen orientation on microstructure of the as-provided material and resultant influence of microstructure on hardness, tensile properties and final fracture behavior are examined. Aspects related to the macroscopic mode and the governing intrinsic microscopic features that result from fracture of the steel specimens machined from the two orientations, longitudinal and transverse, are also examined. The microscopic mechanisms governing quasi-static deformation and final fracture behavior of this structural steel are discussed in light of the conjoint influence of test specimen orientation, intrinsic microstructural effects and nature of loading.

On the Specific Role of Microstructure in Governing Cyclic Fatigue, Deformation, and Fracture Behavior of a High-Strength Alloy Steel

In this paper, the results of an experimental study that focused on evaluating the conjoint influence of microstructure and test specimen orientation on fully reversed strain-controlled fatigue behavior of the high alloy steel X2M are presented and discussed. The cyclic stress response of this high-strength alloy steel revealed initial hardening during the first few cycles followed by gradual softening for most of fatigue life. Cyclic strain resistance exhibited a linear trend for the variation of elastic strain amplitude with reversals to failure, and plastic strain amplitude with reversals to failure. Fracture morphology was the same at the macroscopic level over the entire range of cyclic strain amplitudes examined. However, at the fine microscopic level, the alloy steel revealed fracture to be essentially ductile with features reminiscent of predominantly “locally” ductile and isolated brittle mechanisms. The mechanisms governing stress response at the fine microscopic level, fatigue life, and final fracture behavior are presented and discussed in light of the mutually interactive influences of intrinsic microstructural effects, deformation characteristics of the microstructural constituents during fully reversed strain cycling, cyclic strain amplitude, and resultant response stress.

Cyclic Strain Resistance, Stress Response, Fatigue Life, and Fracture Behavior of High Strength Low Alloy Steel 300 M

The focus of this technical manuscript is a record of the specific role of microstructure and test specimen orientation on cyclic stress response, cyclic strain resistance, and cyclic stress versus strain response, deformation and fracture behavior of alloy steel 300 M. The cyclic strain amplitude-controlled fatigue properties of this ultra-high strength alloy steel revealed a linear trend for the variation of log elastic strain amplitude with log reversals-to-failure, and log plastic strain amplitude with log reversals-to-failure for both longitudinal and transverse orientations. Test specimens of the longitudinal orientation showed only a marginal improvement over the transverse orientation at equivalent values of plastic strain amplitude. Cyclic stress response revealed a combination of initial hardening for the first few cycles followed by gradual softening for a large portion of fatigue life before culminating in rapid softening prior to catastrophic failure by fracture. Fracture characteristics of test specimens of this alloy steel were different at both the macroscopic and fine microscopic levels over the entire range of cyclic strain amplitudes examined. Both macroscopic and fine microscopic observations revealed fracture to be a combination of both brittle and ductile mechanisms. The underlying mechanisms governing stress response, deformation characteristics, fatigue life, and final fracture behavior are presented and discussed in light of the competing and mutually interactive influences of test specimen orientation, intrinsic microstructural effects, deformation characteristics of the microstructural constituents, cyclic strain amplitude, and response stress.

The quasi-static deformation and fracture behavior of novel high-strength steel for emerging applications

In this study, the quasi-static deformation and final fracture behavior of Pyrowear 53 is presented and discussed. This novel alloy steel has noticeably improved strength-, ductility- and fatigue-related properties to offer than other competing high-strength alloy steels having near similar chemical composition and processing history. The conjoint influence of composition and secondary processing on intrinsic microstructural effects, stress versus strain response, tensile properties and final fracture behavior are highlighted. The macroscopic fracture mode and microscopic features on the tensile fracture surface are presented and discussed in light of test specimen orientation. The intrinsic microscopic mechanisms governing tensile deformation and final fracture behavior of this novel steel are discussed in light of the role played by intrinsic microstructural features, deformation characteristics of the microstructural constituents and nature of loading.

Interpretation of stress-strain curve in pipeline research

For the design of on-shore pipelines installed in areas that are susceptible to ground movements and offshore pipelines, axial stresses above yield must be considered. In such so-called strain-based design,knowledge of the stress-strain behaviour of the pipeline steel and girth welds is highly important. These behaviours are influenced by many factors, including: welding parameters, operation temperature, tensile test specimen geometry and orientation, and microstructure of the steel. This paper focuses on the influence of the tensile test specimen geometry and orientation, for the case of UOE formed pipes. As regards the geometry, it is concluded that the stress-strain diagram is most representative for a flat fullthickness test specimen. As regards the orientation, the yield stress is higher for transversal test specimens, as compared to longitudinally oriented test specimens.

A study of cyclic fatigue, damage initiation, damage propagation, and fracture of welded titanium alloy plate

In this paper, the influence of test specimen orientation and microstructure on cyclic stress-amplitude controlled fatigue response, damage initiation, damage propagation and fracture behavior of samples taken from a welded plate of titanium alloy is presented and discussed. Test specimens from the chosen alloy were prepared from an as-welded plate of the material with the stress axis both parallel (longitudinal) and perpendicular (transverse) to the deformed (rolling) direction of the plate. The test specimens were cyclically deformed at different values of maximum stress at a constant load ratio of 0.1, and the resultant cycles-to-failure was recorded. The fracture surfaces of the deformed and failed test specimens were examined in a scanning electron microscope to establish the macroscopic fracture mode, the intrinsic features on the fatigue fracture surface and the role of applied stress-microstructural feature interactions in establishing the microscopic mechanisms governing failure.

A Study of the Tensile Deformation and Fracture Behavior of Commercially Pure Titanium and Titanium Alloy: Influence of Orientation and Microstructure

In this paper, the tensile deformation and fracture behavior of commercially pure titanium and the titanium alloy (Ti-6Al-4V) are presented and briefly discussed. Samples of both commercially pure titanium and the Ti-6Al-4V alloy were prepared from the as-provided plate stock along both the longitudinal and transverse orientations. The specimens were then deformed to failure in uniaxial tension. The intrinsic influence of material composition and test specimen orientation on microstructure, tensile properties, and resultant fracture behavior of the two materials is presented. The conjoint influence of intrinsic microstructural features, nature of loading, and specimen orientation on tensile properties of commercially pure titanium and the Ti-6Al-4V alloy is highlighted. The fracture behavior of the two materials is discussed taking into consideration the nature of loading, specimen orientation, and the role and contribution of intrinsic microstructural effects.

재생냉각 연소기 챔버 제작용 구리합금의 성형성 평가

액체로켓 연소기 재생냉각 챔버의 제작에 사용되는 구리합금의 성형한계 곡선을 얻기 위하여 돔 장출 시험과 인장시험을 수행하였다. 성형한계 곡선에 대한 실험적인 연구를 위하여 인장시편을 사용하여 인장-압축 변형률 상태의 데이터를 얻었으며, 인장-인장의 변형률 상태를 얻기 위하여 돔 장출 시험용 시편을 사용한 돔 장출 시험 또한 수행하였다. 시험에 사용한 모든 시편은 제작방향에 따라 종 방향과 횡 방향시편으로 구분하였다. 시험 결과 인장-인장 변형률 상태에서 최대 주 변형률과 부 변형률은 62.3%와 58.6%이며, 인장-압축 상태에서는 60.5%와 25.8%로 나타났다. The dome stretching tests and tension tests have been performed to obtain a forming limit curve(FLC) for the copper alloy which is used for manufacturing the regenerative cooling thrust chamber. For experimental investigation of the forming limit curve, we have used in-plane tension specimen to obtain tension-compression strain state as well as out-of-plane specimen to obtain tension-tension strain state through dome stretching test. All specimens were divided into longitudinal and transverse directions according to the orientation of test specimen. The test results showed that in the tension-tension region, copper alloy revealed a maximum major strain of 62.3% and a maximum minor strain of 58.6%. In the tension-compression region, the maximum major strain and the maximum minor strain were measured to be 60.5% and 25.8%, respectively.

Effect of Anisotropy on Compressive and Tensile Properties of Asphalt Mixtures

Abstract The research effort in this paper was part of the Superpave Support and Performance Models Management Project (Advanced Material Characterization) and was funded by the National Cooperative Highway Research Program Project 9–19. Anisotropy of hot mix asphalt materials greatly depends on specimen preparation, testing conditions, and test parameters under consideration. The objective of this study was to evaluate the anisotropy of selected test properties for specimens specially prepared with the Superpave gyratory compactor and cored in the vertical, horizontal, and diagnonal directions. The number of gyrations during compaction was adjusted on a trial-and-error basis to produce cores having air void contents of 4.0 ± 0.5% regardless of the direction of coring. Confined compression and tension tests were performed on the cored test specimens. The analysis included parameters such as the compressive / tensile strength, modulus of elasticity, and strain at failure. All test results were analyzed statistically. The majority of the test results (compression and tension) showed no significant effect of test specimen orientation on the test parameters at the 5% level of significance and for the test conditions used in the study. These results indicated that anisotropic effects might be ignored for the asphalt mixture used in this study using the special preparation method in the Superpave gyratory compactor.

Tensile and fracture properties evaluation of PHT system piping material of PHWR

The aim of this paper is to report the tensile and fracture properties of SA333 Gr.6 carbon steel material which is used for the primary heat transport (PHT) system piping of the Indian pressurized heavy water reactor (PHWR). Tensile and J integral tests have been carried out on specimens machined from the base material as well as weldments of actual PHT pipes. The effects of test temperature and specimen orientation on the material properties have been discussed.

The marginal shear stress of Ice Stream B, West Antarctica

AbstractTo ascertain whether the velocity of Ice Stream B, West Antarctica, may be controlled by the stresses in its marginal shear zones (the “Snake” and the “Dragon”), we undertook a determination of the marginal shear stress in the Dragon near Camp Up B by using ice itself as a stress meter. The observed marginal shear strain rate of 0.14 a−1is used to calculate the marginal shear stress from the flow law of ice determined by creep tests on ice cores from a depth of 300 m in the Dragon, obtained by using a hot-water ice-coring drill. The test-specimen orientation relative to the stress axes in the tests is chosen on the basis ofc-axis fabrics so that the test applies horizontal shear across vertical planes parallel to the margin. The resulting marginal shear stress is (2.2 ± 0.3) × 105Pa. This implies that 63–100% of the ice stream’s support against gravitational loading comes from the margins and only 37–0% from the base, so that the margins play an important role in controlling the ice-stream motion. The marginal shear-stress value is twice that given by the ice-stream model of Echelmeyer and others (1994) and the corresponding strain-rate enhancement factors differ greatly (E≈ 1–2 vs 10–12.5). This large discrepancy could be explained by recrystallization of the ice during or shortly after coring. Estimates of the expected recrystallization time-scale bracket the ∼1 h time-scale of coring and leave the likelihood of recrystallization uncertain. However, the observed two-maximum fabric type is not what is expected for annealing recrystallization from the sharp single-maximum fabric that would be expected in situ at the high shear strains involved (γ ∼ 20). Experimental data from Wilson (1982) suggest that, if the core did recrystallize, the prior fabric was a two-maximum fabric not substantially different from the observed one, which implies that the measured flow law and derived marginal shear stress are applicable to the in situ situation. These issues need to be resolved by further work to obtain a more definitive observational assessment of the marginal shear stress.

The marginal shear stress of Ice Stream B, West Antarctica

AbstractTo ascertain whether the velocity of Ice Stream B, West Antarctica, may be controlled by the stresses in its marginal shear zones (the “Snake” and the “Dragon”), we undertook a determination of the marginal shear stress in the Dragon near Camp Up B by using ice itself as a stress meter. The observed marginal shear strain rate of 0.14 a−1is used to calculate the marginal shear stress from the flow law of ice determined by creep tests on ice cores from a depth of 300 m in the Dragon, obtained by using a hot-water ice-coring drill. The test-specimen orientation relative to the stress axes in the tests is chosen on the basis ofc-axis fabrics so that the test applies horizontal shear across vertical planes parallel to the margin. The resulting marginal shear stress is (2.2 ± 0.3) × 105Pa. This implies that 63–100% of the ice stream’s support against gravitational loading comes from the margins and only 37–0% from the base, so that the margins play an important role in controlling the ice-stream motion. The marginal shear-stress value is twice that given by the ice-stream model of Echelmeyer and others (1994) and the corresponding strain-rate enhancement factors differ greatly (E≈ 1–2 vs 10–12.5). This large discrepancy could be explained by recrystallization of the ice during or shortly after coring. Estimates of the expected recrystallization time-scale bracket the ∼1 h time-scale of coring and leave the likelihood of recrystallization uncertain. However, the observed two-maximum fabric type is not what is expected for annealing recrystallization from the sharp single-maximum fabric that would be expected in situ at the high shear strains involved (γ ∼ 20). Experimental data from Wilson (1982) suggest that, if the core did recrystallize, the prior fabric was a two-maximum fabric not substantially different from the observed one, which implies that the measured flow law and derived marginal shear stress are applicable to the in situ situation. These issues need to be resolved by further work to obtain a more definitive observational assessment of the marginal shear stress.

Corrosion Fatigue Crack Propagation Behavior of a C-Mn-Cb Steel

The fatigue crack propagation properties of a C-Mn-Cb plate steel (SA633 Grade C) in a 3.5 percent NaCl solution have been evaluated for loading frequencies of 10, 1.0, and 0.1 Hertz. To reveal the influence of test specimen orientation and steel cleanliness, both a conventional sulfur level and a low sulfur-calcium treated plate were examined in the three major testing orientations. In addition to other basic testing of the plates, the elastic-plastic fracture toughness properties were also established. The fatigue crack growth rates at 0.1 Hz of both steels were increased by factors of 2–5 over air data, depending on the ΔK level and specimen orientation; some increase was also noted at 1.0 Hz. The acceleration due to the salt water environment was a result of a hydrogen embrittlement mechanism which resulted in bursts of faceted, cleavage-like, transgranular fracture of ferrite grains in this ferrite-pearlite steel. At higher ΔK levels, the calcium treated steel showed slower growth rates than the conventional sulfur level steel for all testing conditions. It was found that higher oxygen contents of a salt water solution could lead to corrosion product wedging at low ΔK levels, which could retard crack growth.

The toughness of high hardness laminar composite steel as influenced by specimen and crack orientation

The toughness behavior of high hardness laminar composite steel (high carbon, ∼ Rc 60, hard layer metallurgically bonded to a medium carbon ∼Rc 50, softer layer) was investigated. The effort focused on the effect of test temperature, specimen orientation and crack location on toughness. Charpy V-notch specimens with the notch extending through both the hard and soft layers were tested over a series of temperatures to provide transition curves for both the longitudinal and transverse direction. These transition curves are compared to those obtained from specimens that were surface notched on either the hard or soft side. By precracking similarly oriented specimens, information on the fracture toughness (KQ andW/A) was obtained over approximately the same temperature range. These data show the effect of the interface between the hard and soft layer on the various toughness parameters. Lastly, stress corrosion cracking was investigated andKISCC values provided.