Key Engineering Materials Vols. 462-463

Abstract: The objective of this work was to carry out tensile tests to investigate the effect of finishing temperature on mechanical adhesion of thermal oxide scale on hot-rolled low carbon steel strips. Two hot-rolled low carbon steel strips were produced in an industrial hot rolling line by fixing a coiling temperature at 620 °C and varying finishing temperatures at 820 and 910 °C. Two testing methods were conducted. First, each of a number of samples was subjected to a given imposed strain with ex-situ imaging of scale surface after straining. Second, only one sample was strained in a test with ex-situ imaging of scale surface at every 2 mm elongation of the sample. A spallation ratio, an area where scale was spalled out and normalised by the total area observed by microscope, was plotted as a function of the imposed strain. These two methods gave the same tendency of results as follows. At a given strain, the spallation ratio of scale on steel produced using higher finishing temperature was larger. The gradient of spallation ratio with respect to the imposed strain of that scale was also steeper. This reflects the higher susceptibility of scale to spall out with increasing imposed strain. This behaviour might be related to the larger thickness of scale on steel produced using higher finishing temperature. For the second testing method, lowering the magnification of microscope to observe scale spallation from 50x to 20x increased R2 of the curve of spallation ratio versus the imposed strain, as well as improved the reproducibility of the test.

Abstract: The earthquake and tsunami that struck Aceh region on December 2004 caused many public buildings submerged by seawater. In long periods, it will promote the premature failure of the existing buildings constructed by reinforced concrete structure due to corrosion. Early detection of the corrosion is urgent. The corrosion assessment using haft-cell potential mapping has been conducted to understand the current status of public buildings after five years tsunami Aceh 2004. The results for four existing public buildings in the region show that the corrosion level of steel in concrete of the buildings was already at intermediate risk. However, these results show only the corrosion risk instead of the actual corrosion of the steel. To improve the corrosion assessment, BEM was employed by simulating some factors that might affect the measured potential on the concrete surface. Laplace equation is used to model the potential in concrete structure. The steel surfaces were represented by using polarization curves. BEM is employed to solve the Laplace equation; hence the potential and current density in the whole domain can be obtained. The simulation results show that the potential corrosion on concrete surface was significantly affected by corrosion of steel, concrete conductivity and concrete cover. Accordingly, by employing BEM, more precise corrosion of steel in concrete can be identified from the measured potential on the concrete surface. Moreover, further study is needed to apply the proposed method in the field.

Abstract: It is compulsory to have a good fatigue life to a component that is heavily subjected to cyclic loading. One of the good examples is parabolic spring, which is one of the components in suspension system for large vehicles. It serves to absorb, store and release back the damping energy due to road irregularity, bump and holes. These activities involve a lot of camber deflection that caused by the tension and compression loads. In reality, the loading that subjected to parabolic spring is variable amplitude loading, but most of the manufacturer used constant amplitude (CA) loading for the fatigue test. The objective of this paper is to relate the simulation result with the microstructure behaviour of the leaf spring that failed due to fatigue. A full scale fatigue test was carried out until that parabolic spring meet failure. In order to investigate the fatigue life, CA signal was generated based on an actual fatigue test on the parabolic spring, and it was then analysed using the FEA-based fatigue simulation. A microstructure study was then performed for both fracture and non-fracture area. From the FEA-based simulation, it gave the prediction on damage that occurred at the critical area and also the prediction on the lowest cycle with respect to the FEA model. In the actual fatigue test, the failure was occurred at the centre part of the spring, which is at bolt join of assembly hole. The microstructure analysis showed that the grain at the fracture area indicated some different from the non-fracture area in term of size, phase and precipitation of carbon.

Abstract: There are clear experimental evidences of the formation of either spherical or platelet γ-precipitates inside cubic γ’-precipitates in nickel-based superalloys, which strengthen the mechanical property of the alloy. In this work, molecular statics (MS) and dynamics (MD) simulations of the interaction between a super edge dislocation and a γ-precipitate in γ’-precipitates were performed. The strengthening mechanism was then investigated by comparing the simulation results with the theoretical prediction. As the result, it could be found that the critical resolved shear stress (CRSS) of the interaction has a strong dependence on the shape of the γ-precipitate, and could be well predicted by the theory of precipitation strengthening. Especially, the stacking-fault, chemical, coherency and interface strengthening play a major role in determining the CRSS. Finally, the interaction under a finite temperature was simulated using the MD simulations. It was found that the influence of temperature on the interaction is negligibly small.

Abstract: Fracture in heat affected zone (HAZ) in welding has been a serious problem for the integrity of machines. Prediction of fracture behavior due to the residual stress field in HAZ is important. In this paper, S-Version FEM(S-FEM) is applied to simulate the crack growth under thermal and residual stress fields. For evaluation of stress intensity factor, virtual crack closure integral method (VCCM) is employed. In order to confirm the validity of this analysis, numerical results are compared with previously-reported analytical and experimental results. Then, crack growth analysis in piping structure with welding joint was conducted. The residual stress data was provided by JAEA, Japan Atomic Energy Agency, based on their numerical simulation. Using S-FEM, two- and three-dimensional analyses are conducted, and crack growth behavior under thermal stress field is studied and discussed.

Abstract: Recent development of crack propagation analysis is rapidly advanced and its applications are being extended. Usually finite element method is utilized for the analysis. One of the most important tasks is mesh generation which requires fully automated system and no failures. It is very difficult to meet all geometrical and mechanical requirements for a surface mesh generation. Recent studies show a factory roof is easily generated under mixed mode loading. How to generate surface crack tetrahedral mesh without failures and surface crack analysis with factory roof are presented.

Abstract: Crack propagating evaluation is needed to predict and prevent structural damages since many structure defects from numerous crack propagating. It is widely known that ductile fracture occurs when external load is exerted to the material, these load include strong and unpredictable load such as earthquakes and collision of objects. Ductile material fractures via nucleation of void, growth of void and coalescence of voids. Many studies have been conducted; Kikuchi and Sannoumaru have published papers on the studies of ductile fracture. In the first paper [1], the thickness effect on the microscopic fracture process and fracture toughness is studied experimentally. In the second paper [2], dimple fracture tests were performed using three point bending specimens. In the test, loading condition is changed from mode I to mixed mode condition to study the effect of the mixed mode loading. Numerical simulation is conducted using Gurson’s constitutive equation. It is found that crack growth direction is affected significantly by the loading condition. Ductile fracture of a pipe used in Light Water Reactor components is researched in this paper. Four point bending of a pipe experiment had been done by the Central Research Institute of Electric Power Industry [3]. They were experimented in two conditions; one at room temperature (23 ) and second at high temperature (300 ). As a result, crack propagation behavior differs largely form each other. At room temperature, crack propagates parallel from the pre crack, and at high temperature, crack propagates in a slanting direction from the pre crack. Results show that that difference from the two temperature distinction of a tensile test in a stress strain curve is very little. In this paper, this problem is studied at first by experiments, observation of fracture surface and numerical simulation.

Abstract: This paper presents the dynamic growth behavior of the voids in ductile metals under dynamic loading condition. Started from energy conservation law, a dynamic damage model on void growth process is developed, in which inertial effect is taken into account. The proposed model on void growth is introduced into Gurson model through VUMAT subroutine, so the void growth behavior affected by inertial effect can be investigated and compared. Numerical analysis shows that inertial effect decreases the rate of void growth, and with the increasing of the loading rate, the decreasing effect becomes more remarkable. Inertial effect is very sensitive to the initial damage of the material and the distribution of the void density. The larger the initial damage and the sparser the void density, the stronger the inertial effect on the void growth.

Abstract: Circular inclusion exists widely in natural media, engineering materials and structures, and defects are usually found around the inclusion. When a composite material with circular inclusion and cracks is impacted by the dynamic load, on the one hand, the scattering field produced by the circular inclusion and cracks determines the dynamic stress concentration factor around the circular inclusion, and therefore determines whether the material is damaged or not; on the other hand, the scattering field also presents many characteristic parameters of the inclusion and cracks such as defect composition, location and shape, so the research on the scattering far-field is important to the geological prospects, seismological investigation, non-destruction evaluation and the other fields. In the ocean acoustics, the scattering far-field of the acoustic wave is also used in the under-water survey, object distinguishing and so on. In theory, the scattering solution of elastic waves is one of the basic topics of reverse problems on elastic wave. On the basis of literature, few paper concentrates on the scattering far-field solution of SH-wave by a circular inclusion and a linear crack around the inclusion. In the paper a new model and a new method are presented in order to investigate deeply on this kind problem. The paper uses the Green’s function to study the scattering far-field of an elastic wave by a circular inclusion and a linear crack. The Green’s function should be a fundamental solution of displacement field for an elastic space possessing a circular inclusion while bearing out-of-plane harmonic line source force at any point. In terms of the solution of SH-wave’s scattering by an elastic space with a circular inclusion, anti-plane stresses which are the same in quantity but opposite in direction to those mentioned before, are loaded at the region where the linear crack is in existent actually; Then, the expressions of the displacement and stresses are given when the circular inclusion and linear crack exist at the same time. When the special Green’s function has been constructed and close field solution has been illustrated, the far field of scattered wave is studied. The displacement mode of scattered wave at far field and scattering cross-section are given. At last, an example is given and its numerical results are discussed.

Abstract: The wavelet transform is well known for its ability in vibration analysis in fault detection. This paper presents the ability of wavelet transform in fatigue data analysis starts from high amplitude events detection and it is then followed by fatigue data extraction based on wavelet coefficients. Since the wavelet transform has two main categories, i.e. the continuous wavelet transforms (CWT) and the discrete wavelet transform (DWT), the comparison study were carried out in order to investigate performance of both wavelet for fatigue data analysis. CWT represents by the Morlet wavelet while DWT with the form of the 4th Order Daubechies wavelet (Db4) was also used for the analysis. An analysis begins with coefficients plot using the time-scale representation that associated to energy coefficients plot for the input value in fatigue data extraction. Ten extraction levels were used and all levels gave the damage difference, (%∆D) less than 10% with respect to original signal. From the study, both wavelet transforms gave almost similar ability in editing fatigue data but the Morlet wavelet provided faster analysis time compared to the Db4 wavelet. In comparison to have the value of different at 5%, the Morlet wavelet achieved at L= 5 while the Db4 wavelet at L=7. Even though it gave slower analysis time, both wavelets can be used in fatigue data editing but at different time consuming.