Papers by Author: Keisuke Tanaka

Abstract: Electron backscattering diffraction, EBSD, technique as well as atomic force microscopy, AFM, was employed to investigate fatigue damage mechanism in ultrafine-grained copper processed by equal channel angular pressing, ECAP. The fatigue damage evolution under axial tension compression was investigated. The results show that linearly shaped fatigue damage was introduced in the scale of micrometers in spite of the average grain size of 300 nm. The linear damage was randomly oriented when the shear direction of the last ECAP-pressing in perpendicular to the loading axis. The orientation analysis by EBSD revealed that the linear damage is introduced in the area with the same crystallographic orientation in the direction of the maximum Schmid factor as in the slip deformation in coarse-grained materials. The comparison before and after fatigue tests shows the grain coarsening in the area where large linear fatigue damage was formed. It is considered that strain concentration at the edge of the slips introduced in a relatively coarse ultrafine grain causes the grain rotation and deformation in the adjacent nano-sized grains, resulting in the grain coarsening and subsequent propagation of the slips in the order of micrometers.

Abstract: Tension-compression fatigue tests under various mean stress conditions were conducted with round bar specimens of short glass fiber reinforced polybuthyleneterephthalate made by injection molding. Under cyclic loading with high mean stresses, the creep phenomenon became predominant and the ratcheting deformation increased with the number of cycles. This phenomenon is characteristic of plastics including short glass fiber reinforced plastics. The experimental data of the fatigue strength at the stress ratios above 0.7 were lower than the prediction based on the modified Goodman diagram. We propose to use the creep rupture strength, σc, instead of the tensile strength, σB, as the strength without mean stress and the parabolic equation for a constant life in the amplitude-mean stress (σa-σm) diagram. Our new design equation for the mean-stress effect on the fatigue strength on plastics is as follows: σa = σw – (σw / σc 2) σm 2, where σw is the fatigue strength at the stress ratio R=-1 and σa is the stress amplitude under a mean stress of σm. We also proposed a method to obtain the constant-life relation from limited experimental data.

Abstract: Both EBSD and AFM methods were used to investigate the active slip systems and fatigue crack initiation behavior in face-centered cubic polycrystalline metal, austenitic stainless steel, SUS316NG, under cyclic torsional loading. Most active slip planes are the primary slip planes having the largest Schmid factor. Grains with slip band cracks or transcrystalline cracks have larger Taylor's factors. On the basis of EBSD and AFM observations, h, the depth of intrusion vertical to the surface, S, and the component of the slip displacement perpendicular to the surface trace, SB, showed a sharp increase at the onset of crack initiation. The critical value of SB at crack initiation was 170 nm.

Abstract: A NiCoCrAlY bond coating was low-pressure plasma sprayed on a stainless steel sub- strate. Zirconia with 8 wt% yttria was deposited on the bond coating using an electron beam-physical vapor deposition (EB-PVD) method. The top coating had the preferred orientation with the h111i axis direction perpendicular to the coating plane. The distribution of the in-plane residual stress in the top coating was measured using laboratory Cr-K X-rays with a progressive layer removal method. The value of the in-plane stresses was determined by the sin2 method after the separation of the 133 and 331 peaks. The distribution of the out-of-plane strain in the top coating was measured using the strain scanning method with hard synchrotron X-rays. The out-of-plane strain was obtained from the 333 peak which had strong intensity due to the preferred orientation. The measured value of the in-plane stress in the top coating was a large compression, and showed a steep decrease near the in- terface between the top and the bond coatings. The distribution of the out-of-plane stress showed a compression, and its magnitude was smaller than that of the in-plane stress.

Abstract: Two kinds of electrodeposited copper foils (thickness is 8 and 20 μm) were loaded statically, and the deformation behavior was observed. In-situ X-ray stress measurement was carried out under tensile loading. Fatigue tests were also conducted to observe the effect of the thickness on the fatigue strength. Change in the line broadening with stress cycles was observed to evaluate the fatigue damage. The tensile strength of 8 μm foil was higher than that of 20 μm foil. When the foils were loaded within elastic region, the stress measured by the X-ray method agreed with applied stress. When the plastic deformation occurred, difference between the measured stress and the applied stress became large. The difference of 20 μm foil was larger than that of 8 μm foil. Fatigue strength of 8 μm foil was also higher than that of 20 μm foil. The value of the full width at half maximum, FWHM, increased rapidly at the first cycle, and then the value became nearly constant. Just before fracture, the value increased again. The change in FWHM corresponded to the change in the accumulated ratchet strain.

Abstract: The strain scanning method was applied to the evaluation of the subsurface distribution of the residual stress beneath the shot-peened surface of an austenitic stainless steel SUS304L which had coarse grains and preferred orientation. The experiment was performed at beam line BL22XU at SPring-8 using monochromatic X-rays of 70.14 keV and a Ge (111) analyzer. The sizes of both incident and receiving slits were 2 × 0.2 mm2. The specimens were annealed or shot-peened and had the dimensions of 20 × 20 × 5 mm3. The grain size was about 37 μm. In order to obtain the diffractions from an enough number of grains, various types of oscillation methods, which were translation, rotation and tilting of the specimen, were examined. The translational oscillation was found to be enough to obtain the accurate strain distribution. By combining the translational oscillation method with the correction to the surface aberration, the subsurface distribution of the residual stress of shot-peened austenitic stainless steel was successfully determined.

Abstract: The TiN films with the thickness of 0.1, 0.2, 0.5, 1.0, and 4.0 µm were coated on a steel substrate by the ion beam mixing method. The film had a strong fiber texture with <001> axis perpendicular to the film surface. The in-plane stress measurement was applicable to the thickness down to 0.1 µm of TiN films. The stress was a compression of around 2 GPa. The compressive stress was found to increase below the surface layer of 20 to 30 nm. Thinner films had a steeper increase of the compressive stress in the very-near surface region. The strain distribution measured by the SV method was nearly constant over the region of the penetration depth between 0.3 and 0.6 µm from the surface. The two-tilt method combined with the surface removal method showed a nearly constant distribution of compression in the subsurface region and a sharp increase near the interface to the substrate.

Abstract: The spallation of thermal barrier coatings (TBCs) is promoted by thermally grown oxide (TGO). To improve TBCs, it is very important to understand the influence of TGO on the spalling stress. In this study ,the TBCs were oxidized at 1373 K for four diferent periods: 0, 500,1000 and 2000 h. The distribution of the in-plane stress in oxidized TBCs, s1, was obtained by repeating the X-ray stress measurement with low energy X-rays after successive removal of the surface layer. The distribution of the out-of-plane stress, s1− s3, was measured with hard synchrotron X-rays, because high energry X-rays have a large penetration depth. From the results by the low and high energy Xrays, the spalling stress in the oxidized TBCs, s3, was evaluated. The evaluated value of the spalling stress for the oxidized TBC was a small tension beneath the surface, but steeply increased near the interface between the top and bond coating. This large tensile stress near the interface is responsible for the spalling of the top coating.

Abstract: Single-edge-notched specimens of ultrafine-grained steel were fatigued. The mean grain size of the steel is about 2 micrometers. Propagation behavior of fatigue cracks was observed with the crack closure. The resistance of the crack propagation of ultrafine-grained steel was larger than that of conventional steels. The crack closure acted as an important role for the larger resistance of fatigue crack propagation. After fatigue tests, stress distribution near the fatigue crack was measured by monochromatic X-rays from synchrotron radiation. The irradiated area was 100 µm x 100 µm. Residual and loading stress distributions ahead of the crack tip and on the crack wake was measured at the maximum stress intensity factor and zero applied load. The stress was determined by sin2ψ method. The measured stress was compared with the value calculated by FEM and the fatigue crack propagation model. The stress distribution at the maximum load and residual stresses agreed very well with the calculated results. The crack opening stress calculated by the residual stresses agreed with the experimental result.