Papers by Keyword: HCF

Abstract: On the one hand, many mechanical components manufactured through additive technologies are optimized in terms of stiffness/weight or strength/weight thanks to lattice structures. On the other hand, the high complexity of these components often impedes further finishing operations and, therefore, the fatigue strength can be compromised. The high surface to volume ratio together with the high roughness, typical of additive manufactured components, promote the crack nucleation. In this paper, the High-Cycle-Fatigue (HCF) behavior of the 17-4 PH stainless steel (SS) was characterized. Cylindrical samples, manufactured via Selective Laser Melting (SLM) with an EOS M280, were tested in the as-build condition through a STEPLab UD04 fatigue-testing machine. In particular, a preliminary quasi-static traction test was performed on a sample to obtain the yield strength (σ_Y = 570 MPa) and the ultimate tensile strength (UTS = 1027 MPa). Fatigue tests were performed on samples at different stress levels in order to characterize the whole Stress-Number of cycles (S-N) curve (Wöhler diagram). More specifically, the stair-case method combined with the Dixon approach were exploited to calculate the fatigue limit (σ_F = 271 MPa). The obtained results were compared with those present in literature for the same material and they are coherent with previous researches

Abstract: The high cycle fatigue life of machined parts is affected by the so-called surface integrity induced by the machining process. To model the high cycle fatigue behaviour of turned parts a probabilistic two-scale continuum damage model is developed. While the macroscopic behaviour of the material is assumed to remain elastic during the fatigue loading, the fatigue prediction is based on the incremental evolution of micro-plasticity and damage. The non-standard initial mechanical state of the material in the sub-surface, viz. the plastic strains and residual stresses fields induced by the machining process are taken into account via an initial step prior to the fatigue loading. As far as the micro-geometry of the surface is concerned, an initial micro-crack distribution depending on the depth and shape of the micro-defects observed is introduced.

Abstract: Using a low temperature turning process with carbon dioxide cooling in the cutting zone a variation of the morphology at the specimen surfaces of the metastable austenitic steel AISI 347 was realized. In LCF and HCF fatigue tests at ambient temperature and 300 °C the influence of the surface morphology on the cyclic deformation behavior and fatigue life was investigated by the measurement of stress-strain hysteresis. An additional magnetic measurement allows the characterization of the phase transformation from paramagnetic austenite in ferromagnetic α´-martensite during the turning processes and during cyclic loading. The surface morphology was studied in detail by SEM and x-ray investigations.

Abstract: Alloy 104 is a novel high strength, α+β titanium alloy primarily aimed at aero-engine fan disc applications. Two microstructural variants of Alloy 104 have been assessed. Room temperature tensile strength and elongation have been investigated alongside a more detailed study of low and high cycle fatigue behaviour. The alloy clearly demonstrated an improved fatigue resistance in both microstructural conditions, whilst maintaining forgeability and a comparable density to Ti-6Al-4V. Furthermore, the alloy has been subjected to a load regime with a hold period at peak loads and proven to be insensitive to dwell fatigue.

Abstract: The austenitic steel X6CrNiNb1810 (AISI 347) was investigated in isothermal total strain-controlled tests at ambient temperature and T = 300 °C in the LCF-and HCF-range. The phase transformation from paramagnetic austenite (fcc) into ferromagnetic α´-martensite ́(bcc) leads to cyclic hardening and to an increase in fatigue life. At 300 °C no α´-martensite formation was observed in the LCF-range and the cyclic deformation behavior depends basically on cyclic hardening processes due to an increase of the dislocation density, followed by cyclic saturation and softening due to changes in the dislocation structure. In the HCF-range an increase in fatigue life was observed due to ε- and α´-martensite formation. Measurements of the mechanical stress-strain-hysteresis as well as temperature and magnetic properties enable a characterization of the cyclic deformation behavior and phase transformation in detail. The changes in the physical data were interpreted via microstructural changes observed by scanning-and transmission-electron-microscopy as well as by x-ray investigations. Additionally electromagnetic acoustic transducers (EMATs) developed from the Fraunhofer Institute of Non-destructive Testing (IZFP) Saarbrücken were used for an in-situ characterization of the fatigue processes.

Abstract: High-cycle-fatigue (HCF) fracture mechanism of nickel-based superalloy IN 792 coated with Pt-modified aluminide outward-diffusion coating is studied with focus on the influence of coating cracks. It is found that cracking of the diffusion coating prior to HCF tests has little influence on the fatigue limit of specimens with thin coating (50 μm) but lowers the fatigue limit of specimens with thick coating (70 μm). By fractographic analysis, three types of fractural modes are established according to their crack initiations: internal, external and mixed. While external fractural mode is related to the propagation of existing cracks in the coating, internal facture initiates often at Ti-Ta-W-rich carbides and/or topological-close-packed (TCP) phases and grainboundaries in the superalloy. Increasing the thickness of diffusion coating or the amplitude stress promotes the fractural mode transition from internal/mixed to external. The influence of precracking of coatings on the HCF fracture mechanism can be qualitatively explained by its influence on the stress intensity factor.

Abstract: The intended aim of the paper was to present a short review of more than 15 years of experience of ITWL in the field of applying the signal of actual rotational speed (aperiodic and oscillation components thereof) to the expert diagnosing of aero-engines, including identification of low- and high-cycle fatigue (LCF, HCF) of critical structural members. What has been presented is some essential metrological bearings of the non-contact technique of measuring the engine’s rpm with some flexible key phasors (i.e. vibrating compressor/turbine blades). Also, methods of numerical analysis of measuring signals, in use nowadays, have been discussed. With the jet engine of the SO-3 type (in use on the TS-11 “Iskra” combat trainer) as an example, are discussed algorithms of both the identification of disadvantageous aeromechanical effects (energy state of the engine - i.e. the source of accelerated HCF wear of structural components) and the early detection of symptoms of fatigue failures to compressor blades and the bearing system. The discussed problems have been illustrated with examples selected as to emphasise practicalities of applying a new source of diagnostic information to ‘actively’ control the process of fatigue wear (HCF + LCF) of engine components and to forecast the engine health/maintenance status.

Abstract: In the present paper examples for propagating and non-propagating conditions of slip bands and short fatigue cracks in a ferritic-austenitic duplex steel are given, which were quantified by means of SEM in combination with automated EBSD. To classify the results within the scope of predicting the service life under HCF- and VHCF-loading conditions a numerical model based on the boundary-element method has been developed, where crack propagation is described by means of partially irreversible dislocation glide on crystallographic slip planes in a polycrystalline model microstructure (Voronoi cells). This concept is capable to account for the strong scattering in fatigue life for very small strain amplitudes and to contribute to the concept of tailored microstructures for improved cyclic-loading behaviour.