Papers by Keyword: Fracture Surface

Abstract: This paper presents a metallographic and fractographic study of AISI 304 austenitic stainless steel subjected to mechanical loading in the sensitized condition. Static three-point bending tests and impact tests were carried out to evaluate how sensitization affects the mechanical response and fracture behaviour of AISI 304. The study compares the initial state of the material with its condition after sensitization at 700 °C for 10 h, with emphasis on changes in plastic deformation and fracture mechanisms. Microstructural evaluation was performed using light microscopy, while Vickers microhardness measurements provided insight into local mechanical changes. Fractographic analysis using scanning electron microscopy revealed differences in fracture surface morphology. Results demonstrate a decrease in microhardness, reduced impact energy, and noticeable differences in fracture morphology following the sensitization treatment, indicating that the heat treatment influences both the mechanical response and failure behaviour of AISI 304.

Abstract: This study investigates the effects of fiber type and hybridization on the tensile properties of epoxy composites produced using the temperature-controlled vacuum-assisted resin transfer molding (VARTIM) method. Tensile strengths and fracture behaviors are examined by fabricating 6-layer glass fiber-reinforced composites [G6], 6-layers carbon fiber-reinforced composites [C6], and hybrid composites consisting of six layers of glass and carbon fibers [H1] and [H2]. The microstructures of the composites are analyzed using an optical microscope, and tensile tests are conducted in accordance with ASTM standards. Tensile tests are performed at a constant speed and room temperature, and the fracture surfaces after tensile testing are analyzed using a Stereo Microscope. The results showed that the highest tensile strength is achieved in the carbon fiber-reinforced composite (CFRP), with an increase of approximately 123% compare to the glass fiber-reinforced composite (GFRP). Hybrid composite exhibits the reduced tensile strength compare to CFRP, with decreases of 23% for H2 and 29% for H1, respectively, whereas, increased the fracture toughness of the tested samples. Additionally, fracture surface analysis reveals that GFRP exhibits incomplete separation of the fractured surfaces, while CFRP shows a brittle and clean fracture surface. This study highlights the significant impact of fiber type and hybridization on the tensile property and fracture behavior of epoxy composite, demonstrating the better tensile performance of CFRP, while improving the fracture toughness and manufacturing cost of both GFRP and Hybrid composite.

Abstract: The study examines the effects of the Friction Stir Processing (FSP) process on the EN AW 5754 aluminium alloy, conducted under underwater conditions. FSP is an innovative technology used to improve the mechanical properties of materials through plastic deformation. Fracture surface analysis is essential for understanding how the process influences the internal structure of the alloy and its behaviour during fracture. The results obtained from the fracture analysis provide insights into the deformation mechanisms and how processing conditions affect the material's structural integrity. This study contributes to the development of aluminium alloys with enhanced properties, with applications in fields such as the automotive and aerospace industries.

Abstract: This study explored eggshells as an eco-friendly and cost-effective material for synthesizing hydroxyapatite. The phase compositions and morphological structure of polylactic acid composite with and without co-doped hydroxyapatite addition via a melt blending approach were evaluated. Furthermore, the biodegradation profile of the polylactic acid composite in phosphate buffer solution was studied. The concentrations of PLA/HAp, PLA/7.5MgO-7.5ZnO, and PLA/12.5MgO-2.5ZnO samples, respectively, were examined in this study. The results of morphological evaluation showed a well-distributed irregular spherical phase of hydroxyapatite. Meanwhile, the co-doped hydroxyapatite phases have variations in sizes and shapes. The polylactic acid composites showed fractured, rough, and honeycomb surfaces with interconnected pores suitable for cell propagation and enhancement, and the elemental composition proved precipitation of apatite formation. Characteristics of absorption bands of the hydroxyapatite, magnesium, zinc, and polylactic acid were present, respectively. The XRD spectra confirmed the presence of crystalline and semi-crystalline structures with percent crystallinity of 48.57%, 56.64%, and 60.08%, respectively. Meanwhile, the addition of the co-doped hydroxyapatite results in shifts in the 2θ angles of the crystal phases. The biodegradation study revealed the beneficial role of reinforcing polylactic acid composite with biogenic hydroxyapatite and hybrid doped hydroxyapatite as fillers and their synergetic effect with the pH of 7.08±0.21, 6.63±0.46, & 7.28±0.44, the porosity of 52.26±7.29, 48.57±6.74, & 43.72±5.07 %, and the degradation rate (weight loss) of 51.83±7.03, 48.16±6.85, & 43.66±5.46, respectively. Findings revealed that the current study aligns with the sustainable biodegradable composite used in bone tissue repair and hence contributed towards sustainable material without polluting the environment.

Abstract: High-pressure die-casting (HPDC) can be a productive process for high-quality cast aluminium alloy components. However, it is also a process prone to generate defects, such as gas porosities and incomplete fillings, resulting in rejections. One way to reduce the reject rate is to employ Semi-Solid Metal processing with HPDC. The most important advantages of Semi-Solid alloys are reduced shrinkage defects, fewer gas porosities, and fewer chances of filling-related problems. To take full advantage of a semi-solid metal slurry, the casting process must be controlled meticulously to reach homogeneous casting quality and high process repeatability. A study has been conducted on cast parts composed of two-dimensional symmetrical cavities. From the mechanical tests, unexpected differences emerged in both tensile strength and fracture elongation, which were confirmed by differences in the microstructure. The paper investigates the reasons for the asymmetry in the proprieties to avoid similar problems in future studies and maximize the effectiveness and repeatability of the high-pressure die-casting process.

Abstract: Induction-heated steel has hard and soft layers. These layers can cause an internal fatigue crack originating from the boundary of these layers when cyclic stress is applied. Repeated heating is known as a method for improving fatigue strength, and it was applied to induction heating method. Repeatedly induction-heated steel had high fatigue strength compared to single quenching. We performed rotating bending fatigue tests of low carbon steel (JIS-S45C) induction-heated three times, and observed the fracture surfaces and the microstructures of internal fatigue cracks. The internal fatigue cracks originated from the area around the boundary between soft and hard layers surrounding crack origin. Some pearlite and ferrite can be seen. There were pearlite and dimples on the soft layer of internal fatigue crack and clear grains on the hard layer of the crack. From chase-up observation, we revealed that internal fatigue crack originated from soft layer.

Abstract: Under high cycle and very high cycle fatigue, high strength steels break as a result of internal fracture from inclusions. In order to understand this fracture, “Fisheye” crack has been investigated. In our previous work we found that cracks grew from the boundary between the hard surface and soft core of case-hardened S45C, SUJ2 and SCM415 steel bars under rotating bending fatigue. These cracks were called “Transition area origin (TRO)” cracks. In this study, we closely observed the fracture surface of TRO crack areas in carburized JIS SCM415 specimens (under 734, 776 and 865 MPa). We found three features of the TRO cracks: outside of the TRO cracks had asperities; the shapes of TRO cracks were almost circular, and were different from those in S45C and SUJ2 steels; and the HAZ-TRO area which was located at hardened layer had some ridges, and the Core-TRO area at unheat-treated layer was smooth and flat.

Abstract: Effects of low angle boundaries (LABs) on the stress rupture properties of bicrystals of a nickel-based third generation single crystal superalloy at 1093 °C/158 MPa were investigated. The results show that the effect of LABs on the stress rupture elongation of the alloy is higher than that of the stress rupture life at 1093 °C/158 MPa. As the misorientation angle of the LABs reaches 9.0°, the stress rupture life of the alloy with LABs can still retain nearly 50% of that with LABs of 0° at 1093 °C/158 MPa; while the stress rupture elongation of the alloy with LABs drops obviously when the misorientation angle of the LABs is larger than 6.5°. The fracture surfaces of stress ruptured alloy with LABs of 0°~2.9° are characterized by dimple features, while those with LABs of 6.5°~12.3° all exhibit intergranular fracture features. Apparent dimple features can be observed at the intergranular fracture surface of the alloy with LABs of 6.5° and the elongation of it is high. However, obvious dendrite features can be observed at the intergranular fracture surfaces of the alloy with LABs of 7.6°~12.3° and the elongations of them are relatively low.

Abstract: The paper deals with complex material analysis of a shaft after failure. The shaft was operated as part of an "Abradable rig" device used to test the resistance of coatings at high speeds, which simulates a turboprop engine's operating conditions. The shaft is made of 16MnCr5 material with subsequent cementation. The subject of interest is a complex material analysis (i.e. control of the chemical composition of the material and complete fractographic and metallographic analysis) and verification of the shaft design. The aim of the study is a precise determination of the specific cause of component failure.

Abstract: In this study, the effect of surface treatment of Al with alkaline (pH 10.5 and pH 12.4) and acidic (pH 3.7) electrolyzed water was investigated on bonding strength of solid phase diffusion bonded Al. Aluminum hydroxide and hydroxyl groups were appeared on the surface of Al which was treated with alkaline electrolyzed water of pH 12.4 at 323 K for 2700 s. It was found that such treatment is similar to the one with NaOH aqueous solution at 323 K for 30 s. For bonding strength, shear strength of the bonded Al specimens treated with electrolyzed water of pH 12.4 at 293 K for 3 s and 30 s were higher than that of the untreated specimen.