Key Engineering Materials Vols. 577-578

Abstract: A mixed-mode cracked configuration is investigated using the multi-parameter fracture mechanics concept based on the analytical description of the stress/displacement field near a crack tip by means of the Williams series expansion. It is shown that using only one (singular) parameter as it is usual for brittle materials is not sufficient if the accurate stress distribution also further from the crack tip shall be known. Tangential stress distribution in various distances from the crack tip is presented and importance of the higher-order terms of the Williams expansion emphasized. Moreover, initial crack propagation direction is investigated by means of the MTS criterion and utilization of its generalized form is discussed.

Abstract: Results of a fairly comprehensive experimental programme aimed at evaluation of fatigue crack growth (FCG) rates in an aircraft Al 2124 alloy in T851 state, after hot rolling, solution annealing, small plastic strain and artificial ageing are presented and discussed. Measurement was performed not only in the region of stable crack growth, but also in the threshold region enabling to estimate threshold values of stress intensity factor range using method of regression analyses. FCG rates were evaluated in both L-T and T-S directions to evaluate sensitivity of FCG resistance on different microstructure orientation. Different load asymmetry conditions R = F_min / F_max were used, namely R = 0.1 and 0.6. Repeated measurements in more than one specimen at each condition enabled to evaluate reproducibility, scatter of measurement and to perform eventually probabilistic assessment. The reproducibility of measurement was particularly good for L-T orientation. In this case, threshold values were somewhat higher and FCG rates lower in comparison with the T-S orientation. In the contrary, cyclic fracture toughness in T-S orientation was slightly higher. The results are discussed form the viewpoint of residual fatigue life in aircraft components considering probabilistic aspects.

Abstract: Al 7075 alloy is a high strength material usually used for highly stressed components in lightweight structures, typically in aircraft, aerospace and defence applications. It can be applied in different heat treatment conditions, but the T7351 temper state is most widely used because of improved stress-corrosion cracking resistance. An investigation of effects of overloads on fatigue crack growth (FCG) and retardation in Al 7075-T7351 alloy was carried out. FCG rates were measured at load asymmetry R = F_min / F_max = 0.1, in quite wide region of growth between 10^-8 and 10^-5 m/cycle (stress intensity factor range ΔK between 6 and 40 MPa m^1/2). Retardation effects of overloads of the magnitudes 2.7-times and 3.0-times of the maximum load in the constant range fatigue loading were significant. Crack mouth opening displacement was evaluated at numerous stages of crack growth including pre-cracking with so called load shedding method. The overloads resulted in substantial crack closure effects, which, however, did not occur immediately after the overloading, but after further fatigue crack extension. Results are discussed considering both theoretically and experimentally estimated plastic zone size and considering crack closure issues recently published in the literature

Abstract: The cold-working expansion methods are extensively used in the aerospace and mechanical industry to obtain forced couplings of steel bushings into holes made on mechanical components, by means of the passage of an oversized mandrel. This work describes a calculation algorithm, able to correlate the selected interference level, as the difference between the maximum radius of the mandrel and the inner radius of the bushing, to the residual stresses expected on the hole surface. The designer, taking into account the different design choices already made, can choose the optimal interference, estimating the uncoupling resistance and the fatigue strength of forced components. Two original and different systems bushing-mandrel, in low and high interference, have been tested for determining the characteristics of fatigue resistance in the finite life part of the Wohlers diagram.The results have been compared with previously estimated data, getting a good agreement of the series. The increase of the adopted interference value determine a corresponding increase of residual stresses on the hole, both in the radial than in the circumferential direction, and an appreciable and predictable improvement of the fatigue strength of components.

Abstract: The IHX (Intermediate Heat Exchanger) of a VHTR (Very High Temperature Reactor) transfers 950°C heat generated from the VHTR to a hydrogen production plant. The Korea Atomic Energy Research Institute (KAERI) has manufactured a 70 kW class lab-scale PCHE (Printed Circuit Heat Exchanger) prototype made of SUS316L under consideration as a candidate. In this study, as a part of a structural integrity evaluation of the lab-scale PCHE prototype, an elastic structural analysis including structural analysis modeling and a thermal/elastic structural analysis was carried out under the test conditions of a helium experimental loop (HELP). In addition, a structural integrity evaluation considering the weld material properties was conducted.

Abstract: Some designs of nuclear reactors involve a graphite moderator within their core. Different forms of graphite have been adopted in the UK gas-cooled reactors but all have a complex structure of filler particles, matrix and pores. Changes occur in the graphite during service and in particular, porosity increases from that found in the virgin material. As part of a structural assessment, it is important to analyse the effects of this change in porosity. Software has been developed to represent the microstructure of pile grade A (PGA) and Gilsocarbon graphite with a range of porosities, to support finite element determination of material properties. The models are three dimensional geometric and voxel models based on the observed microstructures of these different graphites. Creating a sequence of model specimens with increasing porosities while holding other parameters constant, provides a representative microstructure to test the effect of increasing porosity on mechanical and physical properties.

Abstract: In this study, the three-dimensional and nonlinear finite element method is used to estimate the performances of bonded composite repairs of metallic cracked aircraft structures by analyzing the J integral and at the crack tips of repaired cracks for single and double symmetric patches. Several calculations have been realized to extract the plasticized elements around the crack tip. The obtained results show that composite repair reduces significantly the J integral at the crack tip which can improve the fatigue life of aircraft structures. It was also shown that the double symmetric patch has a considerable beneficial effect on the repair performance compared to the single patch.

Abstract: In orthopedic surgery and particularly in the total hip arthroplasty, the stem fixation is performed in general using a surgical cement which consists essentially of polymer (PMMA). Fracture of cement and prosthesis loosening appears after a high-stress level. This phenomenon origin is due to the presence of micro-cavities in the PMMA volume. The focus of our study is the modeling using the finite-element method of the cement damage around these cavities, the cavities' sizes and shapes effect on the damage risk, and the crack length estimation due to this damage. A small Fortran schedule was incorporated with the Abaqus code to calculate the damage zone. Results show that the presence of a cavity in the cement increases the damage parameter. The damage appears when the cavity is located in cement on the loading axis. If the cavity changes its shape from circular to elliptical, the size of the damage zone increases. One can predict the initiation of a crack in cement with a maximal length of 70μm.Keywords: total hip prosthesis, crack, bone cement, biomechanics, damage.

Abstract: The designs of cemented hip femoral stems have an influence on both the quality of the metalbone cement contact and the failure rate of the cement mantle. Finite element stress technique has been used to optimize both design and material selection in load-bearing components in artificial hip joints based on the static load analysis, by selecting the peak load during the patient activity. In this study, two stem shapes (Ceraver Osteal and Charnley stems) for total hip arthoplasty (THA) were modelled. Static behaviour of these designed stem shapes were analyzed using commercial finite element analysis code ABAQUS. Linear elastic analysis is adapted; Von Mises stress and shear stress are the criterions that are of concern. Results show that, the stresses distribution in the femoral arthroplasty components depends on the material and design of the stem. In addition, the cement-bone and cement-stem interfaces seem to be crucial for the success of the hip replacement, hip prosthesis with Charnely stem induces the more stresses on the interfaces cement.

Abstract: In this paper an experimental investigation has been carried on, in order to determinate the different damage patterns and the corresponding entity on the surface of splined couplings with straight and crowned teeth, subjected to variable working loadings. In particular, experimental tests have performed by means of a dedicated test rig, allowing to realize different working conditions, as the angle between the axis of shaft and hub and also the presence of lubrication. Teeth surfaces after tests have been analyzed by considering as damage parameters both surface roughness and gap between teeth. Results show that the wear pattern on crowned teeth is completely different with respect to the straight ones; in both cases, the value of the misalignment angle and the presence of lubrication may substantially influence the entity of the surface damage.