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At least 289 records · Page 16

Surface integrity and fatigue behaviour of electric discharged machined and milled austenitic stainless steel

Machining of austenitic stainless steels can result in different surface integrities and different machining process parameters will have a great impact on the component fatigue life. Understanding how machining processes affect the cyclic behaviour and microstructure are of outmost importance in order to improve existing and new life estimation models. Milling and electrical discharge machining (EDM) have been used to manufacture rectangular four-point bend fatigue test samples; subjected to high cycle fatigue. Before fatigue testing, surface integrity characterisation of the two surface conditions was conducted using scanning electron microscopy, surface roughness, residual stress profiles, and hardness profiles. Differences in cyclic behaviour were observed between the two surface conditions by the fatigue testing. The milled samples exhibited a fatigue limit. EDM samples did not show the same behaviour due to ratcheting. Recrystallized nano sized grains were identified at the severely plastically deformed surface of the milled samples. Large amounts of bent mechanical twins were observed ~ 5 μm below the surface. Grain shearing and subsequent grain rotation from milling bent the mechanical twins. EDM samples showed much less plastic deformation at the surface. Surface tensile residual stresses of ~ 500 MPa and ~ 200 MPa for the milled and EDM samples respectively were measured. - Highlights: •Milled samples exhibit fatigue behaviour, but not EDM samples. •Four-point bending is not suitable for materials exhibiting pronounced ratcheting. •LAGB density can be used to quantitatively measure plastic deformation. •Grain shearing and rotation result in bent mechanical twins. •Nano sized grains evolve due to the heat of the operation.

36 MATERIALS SCIENCE↗

High cycle fatigue in the transmission electron microscope

One of the most common causes of structural failure in metals is fatigue induced by cyclic loading. Historically, microstructure-level analysis of fatigue cracks has primarily been performed post mortem. However, such investigations do not directly reveal the internal structural processes at work near micro- and nanoscale fatigue cracks and thus do not provide direct evidence of active microstructural mechanisms. In this paper, the tension–tension fatigue behavior of nanocrystalline Cu was monitored in real time at the nanoscale by utilizing a new capability for quantitative cyclic mechanical loading performed in situ in a transmission electron microscope (TEM). Controllable loads were applied at frequencies from one to several hundred hertz, enabling accumulations of 10 6 cycles within 1 h. The nanometer-scale spatial resolution of the TEM allows quantitative fatigue crack growth studies at very slow crack growth rates, measured here at ~10 –12 m·cycle –1 . This represents an incipient threshold regime that is well below the tensile yield stress and near the minimum conditions for fatigue crack growth. Evidence of localized deformation and grain growth within 150 nm of the crack tip was observed by both standard imaging and precession electron diffraction orientation mapping. Finally, these observations begin to reveal with unprecedented detail the local microstructural processes that govern damage accumulation, crack nucleation, and crack propagation during fatigue loading in nanocrystalline Cu.

36 MATERIALS SCIENCE↗

Fatigue crack damage detection using subharmonic component with nonlinear boundary condition

In recent years, researchers have focused on structural health monitoring (SHM) and damage detection techniques using nonlinear vibration and nonlinear ultrasonic methods. Fatigue cracks may exhibit contact acoustic nonlinearity (CAN) with distinctive features such as superharmonics and subharmonics in the power spectrum of the sensing signals. However, challenges have been noticed in the practical applications of the harmonic methods. For instance, superharmonics can also be generated by the piezoelectric transducers and the electronic equipment; super/subharmonics may also stem from the nonlinear boundary conditions such as structural fixtures and joints. It is hard to tell whether the nonlinear features come from the structural damage or the intrinsic nonlinear boundary conditions. The objective of this paper is to demonstrate the application of nonlinear ultrasonic subharmonic method for detecting fatigue cracks with nonlinear boundary conditions. The fatigue crack was qualitatively modeled as a single-degree-of-freedom (SDOF) system with non-classical hysteretic nonlinear interface forces at both sides of the crack surfaces. The threshold of subharmonic generation was studied, and the influence of crack interface parameters on the subharmonic resonance condition was investigated. The different threshold behaviors between the nonlinear boundary condition and the fatigue crack was found, which can be used to distinguish the source of nonlinear subharmonic features. To evaluate the proposed method, experiments of an aluminum plate with a fatigue crack were conducted to quantitatively verify the subharmonic resonance range. Two surface-bonded piezoelectric transducers were used to generate and receive ultrasonic wave signals. The fatigue damage was characterized in terms of a subharmonic damage index. The experimental results demonstrated that the subharmonic component of the sensing signal can be used to detect the fatigue crack and further distinguish it from inherent nonlinear boundary conditions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DETERMINATION OF THE CREEP–FATIGUE INTERACTION DIAGRAM FOR ALLOY 617

Alloy 617 is the leading candidate material for an intermediate heat exchanger for the very high temperature reactor. To evaluate the behavior of this material in the expected service conditions, creep-fatigue testing was performed. Testing has been performed primarily on a single heat of material at 850 and 950°C for total strain ranges of 0.3 to 1% and tensile hold times as long as 240 minutes. At 850°C, increases in the tensile hold duration degraded the creep fatigue resistance, at least to the investigated strain-controlled hold time of up to 60 minutes at the 0.3% strain range and 240 minutes at the 1.0% strain range. At 950°C, the creep-fatigue cycles to failure becomes constant with increasing hold times, indicating saturation occurs at relatively short hold times. The creep and fatigue damage fractions have been calculated and plotted on a creep-fatigue interaction D-diagram. Results from earlier creep-fatigue tests at 800 and 1000°C on an additional heat of Alloy 617 are also plotted on the D-diagram. The methodology for calculating the damage fractions will be presented, and the effects of strain rate, strain range, temperature, hold time, and strain profile (i.e. holds in tension, compression or both) on the creep-fatigue damage will be explored.

36 MATERIALS SCIENCE↗

The Relationship between Workload, Performance and Fatigue in a Short-Haul Airline

Short-haul flights are associated with irregular work schedules and increased workload, due to frequent takeoffs and landings. We examined the relationship between pilot workload, performance and subjective fatigue during normal short-haul operations. Ninety airline pilots (8 female), mean age 33 (±8 years) completed a NASA-Task Load Index (NASA-TLX), a Psychomotor Vigilance Task (PVT; a reaction time test sensitive to sleep loss) and a Samn-Perelli (SP) fatigue scale, over a period of 20 duty days at top-of-descent on 2762 short-haul flights. The duty days included either 2 or 4 flights per day starting at different times as scheduled during normal operations. Workload was measured using the six NASA-TLX scales: mental demand, physical demand, temporal demand, effort, performance and frustration. Lapses (reaction times [RT] > 500ms) were calculated for the PVT. Spearman correlations were calculated to identify relationships between the NASA-TLX, PVT lapses, and SP. The six scales of NASA-TLX were positively correlated with the PVT lapses (p < 0.01) showing an increase in workload when lapses increased. There was a positive correlation between subjective fatigue as measured by the SP fatigue scale and each of the six scales of NASA-TLX (p < 0.001) suggesting that pilots reported higher workload when perceived levels of fatigue were higher. Of the six workload scales, mental demand and performance were rated the highest (mental: M = 40.99, SD = 20.32; performance: M = 41.61, SD = 20.71) and effort was rated the lowest (M = 15.59, SD = 8.98). Preliminary analyses suggest that high workload is associated with poorer PVT performance and increased self-reported fatigue in this population of short-haul pilots. Future studies should explore how other workload factors (i.e. flight hours, time of day) influence self-reported and objective fatigue measures.

TLX↗

Short-Haul Fatigue: Pilot Perspectives & Current Research

Introduction: There are few studies investigating the impact of fatigue in short-haul flight operations conducted under United States (U.S.) Federal Aviation Regulations (FAR) Part 117 flight and duty limitations and rest requirements. In order to understand the fatigue factors unique to short-haul operations, we conducted a series of focus groups across four major commercial passenger airlines in the US. The outcomes of this study were intended to inform the scope of a larger study of fatigue in short-haul operations. Methods: Ninety short-haul pilots were recruited through emails distributed by airline safety teams and labor representatives. Fourteen focus groups were conducted via an online conferencing platform in which participants were asked to identify, specific to short-haul: a) schedules and operations that lead to elevated fatigue; b) schedules and operations that are not fatiguing, and c) important fatigue factors to study. Data were collected anonymously and coded using conventional qualitative content analysis, with axial coding and summative analysis used to identify main themes and over-arching categories. Results: Participants had an average of 12,348 (6,483) lifetime flying hours with 71 (14.5) hours of monthly flying. Forty-six percent of participants were captains. The six fatigue factor categories identified were: circadian disruption (e.g., circadian switches, redeyes), high workload (e.g., hassle factors, number of flights per duty), inadequate rest opportunity (e.g., minimum rest layovers, quality of rest facilities), schedule changes (e.g., unpredictability), regulation and policy issues (e.g., scheduling up to FAR 117 limits), and long sits (e.g., long wait times between flights). Discussion: A field study informed by these results and designed to investigate the prevalence and impact of these factors in US short-haul operations is currently underway.

pilots↗

Fatigue Failure Characteristics of Single-Crystal Fe-3%Al Alloy

To obtain a better understanding of the mechanical properties and failure characteristics of the single-crystal Fe-3%Al alloy (SC), tensile and fatigue properties of the SC and polycrystalline Fe-3%Al alloy (PC) have been investigated. The tensile strength and fracture strain for the SC samples were different depending on the loading direction, i.e., 〈111〉, 〈110〉 and 〈100〉, which could be explained by the Schmid factor. Fatigue strength for the SC samples was basically correlated with their tensile strength. Different fatigue properties were obtained for the PC sample, e.g., the high fatigue strength was obtained in the early fatigue stage, and significant reduction in the fatigue strength was appeared in the later fatigue stage, e.g., low endurance limit at 10{sup 7} cycles. The reason for this was caused by the material brittleness due to the accumulated dislocation at the grain boundaries. Because the high ductile SC samples made severe plastic deformation ahead of the crack tip, the crack growth rate did not enhance even if the high stress intensity factor range was applied in Region II (da/dN versus ΔK). The crack growth rate dropped just before the final fracture. Effective stress intensity factor range was estimated using the crack closure model, but the crack growth rate is found to be affected strongly by the slip system of SC sample.

36 MATERIALS SCIENCE↗

Role of point defects in bipolar fatigue behavior of Bi(Mg{sub 1/2}Ti{sub 1/2})O{sub 3} modified (Bi{sub 1/2}K{sub 1/2})TiO{sub 3}-(Bi{sub 1/2}Na{sub 1/2})TiO{sub 3} relaxor ceramics

Lead-free Bi(Mg{sub 1/2}Ti{sub 1/2})O{sub 3}-(Bi{sub 1/2}K{sub 1/2})TiO{sub 3}-(Bi{sub 1/2}Na{sub 1/2})TiO{sub 3} (BMT-BKT-BNT) ceramics have been shown to exhibit large electromechanical strains under high electric fields along with negligible fatigue under strong electric fields. To investigate the role of point defects on the fatigue characteristics, the composition 5BMT-40BKT-55BNT was doped to incorporate acceptor and donor defects on the A and B sites by adjusting the Bi/Na and Ti/Mg stoichiometries. All samples had pseudo-cubic symmetries based on x-ray diffraction, typical of relaxors. Dielectric measurements showed that the high and low temperature phase transitions were largely unaffected by doping. Acceptor doping resulted in the observation of a typical ferroelectric-like polarization with a remnant polarization and strain hysteresis loops with significant negative strain. Donor-doped compositions exhibited characteristics that were indicative of an ergodic relaxor phase. Fatigue measurements were carried out on all of the compositions. While the A-site acceptor-doped composition showed a small degradation in maximum strain after 10{sup 6} cycles, the other compositions were essentially fatigue free. Impedance measurements were used to identify the important conduction mechanisms in these compositions. As expected, the presence of defects did not strongly influence the fatigue behavior in donor-doped compositions owing to the nature of their reversible field-induced phase transformation. Even for the acceptor-doped compositions, which had stable domains in the absence of an electric field at room temperature, there was negligible degradation in the maximum strain due to fatigue. This suggests that either the defects introduced through stoichiometric variations do not play a prominent role in fatigue in these systems or it is compensated by factors like decrease in coercive field, an increase in ergodicity, symmetry change, or other factors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Photoluminescence fatigue and inhomogeneous line broadening in semi-insulating Tl 6 SeI 4 single crystals

Photoluminescence (PL) properties of semi-insulating Tl 6 SeI 4 have been investigated. A broad emission band centered at 1.63 ± 0.02 eV was observed in all samples. The PL emission band is excitonic in nature and is tentatively attributed to a bound exciton emission. PL fatigue (a reduction in PL intensity under prolonged laser excitation) was always observed. The amount of PL fatigue depended on excitation power and temperature. PL fatigue kinetics are described by a stretched exponential with nominal lifetimes in the 10–265 s range. The recovery of the PL occurred within a few seconds of light cessation. The magnitude of PL fatigue in different samples correlated with inhomogeneous line broadening of the 1.63 eV emission band, such that broader bands exhibited more fatigue. An additional luminescence band centered at 1.78 eV was observed which increased in intensity under prolonged laser irradiation. The fatigue phenomenon is tentatively attributed to two mechanisms—the formation of photo-induced defects and the formation of quasi-stable particles. Both of these mechanisms introduce additional radiative and non-radiative recombination channels that lead to a decrease in the PL intensity under prolonged laser irradiation. Finally, since inhomogeneous line broadening and PL fatigue are related to the concentration of defects or impurities, the measurement of these two parameters is an effective method to screen sample quality.

36 MATERIALS SCIENCE↗

Characterization of Creep-Fatigue Crack Growth in Alloy 709 and Prediction of Service Lives in Nuclear Reactor Components (Final Report)

This final report summarizes the activities and results that were obtained by the research team working on the project “Characterization of Creep-Fatigue Crack Growth in Alloy 709 and Prediction of Service Lives in Nuclear Reactor Components”, DOE-NEUP Project 15-8623. This project was mainly concerned with the creep-fatigue crack growth characterization of austenitic stainless-steel Fe-20Cr-25Ni (Alloy 709). For this purpose, an array of experimental and computational activities was performed. The main goal of these activities was to describe and predict the crack growth behavior in Alloy 709 under different conditions of applied loading and temperature. Alloy 709 specimens were tested to describe both the uniaxial creep behavior and creep-fatigue crack growth rates at temperatures between 550°C and 700°C. Microstructure and fracture surface analysis was performed using several experimental techniques, and the defining features of crack growth propagation were identified and described. Thermodynamic and diffusion simulations were performed to understand the microstructure evolution of Alloy 709 at elevated temperatures, and to establish an aging schedule relevant for in-service conditions over extended periods. Experimental testing was performed on both as-received and aged Alloy 709 specimens. Two computational methods were developed to predict crack growth rates and remaining lives in specimens loaded under either fatigue of creep-fatigue. The first computational technique was the finite element method, while the second was strip-yield modeling. Both methods relied on the prediction of crack growth rates using the concept of plasticity-induced crack closure. Crack-tip opening loads were computed and used to perform crack growth rate predictions. The computational predictions matched well with the experimental results. The strip-yield model was shown to be an excellent predictive tool not only for crack growth in austenitic SS Alloy 709, but also in 316 SS, martensitic Cr-Mo steels, Ni-based alloys and Al-based alloys. The main conclusion of this study is that Alloy 709 exhibits excellent creep crack growth resistance at temperatures between 550°C and 700°C. In fact, the crack growth resistance of this alloy appears to be higher than that of 316 SS in similar testing conditions. Moreover, when creep loading with hold (dwell) times of 60s or 600s were intercalated every fatigue cycle, the crack growth rates did not change significantly. The conclusion is that the tests performed revealed that the crack growth is insignificant during the creep portion of a loading cycle, as compared with the crack growth during the fatigue portion of the cycle. In general, Alloy 709 shows excellent resistance to creep deformations and creep crack growth up to 700°C.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Creep and Creep-Fatigue Crack Growth Mechanisms in Alloy709 — NEUPRC-3.2 (Final Report)

This report is a summary of the work carried out by an interdisciplinary team from USA (Department of Mechanical and Aerospace Engineering, North Carolina State University) and UK (School of Metallurgy and Materials, University of Birmingham) to study creep and creep-fatigue crack growth mechanisms of alloy 709 under plane stress and more constrained ‘plane strain’ conditions. While the US team was funded through the DOE-NEUP program, NEUP RC 3.2, 15-8432 the UK team was funded through Research Council UK Energy Program (RCUKEP) award number EP/N016351/1. The UK team’s program ends in September 2019, while the US program ends in December 2018. As such some of the activities of the program will continue till late 2019. The USA team utilized a novel technique including in-situ heating - loading and Scanning Electron Microscope (SEM) imaging to study the “real-time” crack growth of alloy 709 under plane stress conditions, while the UK team focused on ex-situ fatigue, creep and creep fatigue on larger samples under constrained conditions. Transmission Electron Microscope (TEM) characterization of samples before, during and after creep and creep-fatigue testing was used to address local deformation behavior, dislocation analysis and damage evaluation. Attention was directed towards establishing micro-mechanisms of fatigue crack growth, crack growth under dwell fatigue loading, creep and creep-fatigue crack growth at temperatures ranging from 500 to 750°C in air and in vacuum.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Microstructural Model for Creep-Fatigue Interaction in Grade 91 Steel

This report describes the completion of a crystal plasticity finite element simulation framework for creep-fatigue deformation and damage in Grade 91 steel. In addition to a description of the framework and a set of verification calculations, the report details an initial set of simulations applying the framework to examine low cycle fatigue and creep-fatigue interaction in Grade 91 at 600° C. Grade 91 is a likely material for future advanced microreactors and creep-fatigue will be a limiting structural damage mechanism, particularly for mobile reactors or load following systems. The framework described here could provide a better understanding of creep-fatigue damage mechanisms and directly examine creep, fatigue, and creep-fatigue interaction for Grade 91 at realistic component service conditions. This in turn could lead to improved design methods and component life estimation approaches, leading to more efficient and economical component designs.

36 MATERIALS SCIENCE↗

Uncertainty Quantification of Monolithic Tungsten Target Block Fatigue

The current STS spallation target design consists of 21 water cooled, tantalum clad, monolithic tungsten blocks. The target wheel assembly rotates such that each target block receives a direct proton pulse every 1.4 seconds (21 blocks / 15 Hz pulses). The quasi-steady heating induced by the repetitive beam pulses creates a significant mean stress distribution in the target. On top of this, the rapid energy deposition from a proton pulse induces dynamic stress waves that are of the same order of magnitude as the mean stresses. Over the design goal of 5,000 operational hours per year for a decade, each target must withstand over 130 million repetitions of these dynamic stress events. The fatigue life prediction of the target blocks is a complex sequence of simulations that depend upon a set of input parameters. For the tungsten block, the end goal is the fatigue factor-of-safety (FOS). This study documents a new structural analysis routine using software available to U.S. national laboratories (e.g. CUBIT, Sierra Multiphysics, Dakota) that enables more rapid target fatigue analysis. The increased throughput is amenable to parameter sensitivity and uncertainty quantification (UQ) studies. A set of input parameters (ultimate strength, fatigue strength, density, elastic modulus, Poisson’s ratio, thermal conductivity, coefficient of thermal expansion, specific heat, flow rate) with expected ranges are documented based on literature data, recent experimental testing, and engineering judgement. UQ bounds the resulting fatigue FOS at [0.5, 3.4] using epistemic interval analysis. These bounds are expected to be wider due to model effects (discretization) and beam effects (focus, offset) that were not included. Parameter sensitivity underscores the importance of ultimate strength and fatigue strength of irradiated tungsten on the fatigue calculations.

43 PARTICLE ACCELERATORS↗

Fatigue-crack initiation and growth in notched 2024-T3 specimens monitored by a video tape system

Fatigue-crack initiation and early stages of growth in notched 2024-T3 aluminum alloy sheet specimens were monitored during constant-amplitude fatigue tests conducted for a range of stress ratios. A video tape system was developed to detect fatigue cracks 0.1 mm in length on the sheet surface and to monitor their growth. Fatigue cracks initiated either at the notch corner or on the notch surface. Most of the first fatigue cracks started as notch-corner cracks, and the crack-initiation period was defined as the number of cycles for which the crack was 0.1 mm in length on the sheet surface. For each of the stress ratios used, the results showed that at the low stress levels, the crack-initiation period constituted at least 90 percent of the fatigue lives. However, for the negative stress ratios at the high stress levels, cracks started as early as at about 40 percent of the fatigue lives.

Sova, J. A.↗

Rolling-element fatigue life of AMS 5749 corrosion resistant, high temperature bearing steel

The rolling element fatigue lives of AMS 5749 and AISI M-50 were compared in tests run in the five ball fatigue tester and the rolling contact fatigue tester. The effects of double vacuum melting and retained austenite on the life of AMS 5749 were determined in five ball fatigue tests. The double vacuum melting process consisted of induction vacuum melting followed by vacuum arc remelting (VIM-VAR). In the five ball tests, VIM-VAR AMS 5749 gave lives at least six times that of VIM-VAR AISI M-50. Similar tests in the rolling contact fatigue tester showed no significant difference in the lives of the two materials. The rolling element fatigue life of VIM-VAR AMS 5749 was at least 14 times that of vacuum induction melted AMS 5749. A trend toward increased rolling element fatigue life with decreased retained austenite is apparent, but the confidence that all experimental differences are significant is not great.

Parker, R. J.↗

A temperature dependent fatigue failure criterion for graphite/epoxy laminates

A fatigue failure criterion applicable to composite materials is developed and applied to predict the fatigue behavior of graphite/epoxy laminates with particular emphasis on the influence of temperature. Tensile stress-strain curves and tension-tension fatigue curves for various unidirectional, angle-ply and symmetrically balanced laminates were developed at test temperatures of 25 C, 74 C, and 114 C. For most laminates a reduction in both static strength and fatigue strength is observed with increasing temperature. This reduction appeared more severe in fatigue loading than in static tensile loading and most severe where the shear stress in the lamina is the dominate failure mode. Through an analytical formulation of shifting functions for the influences of temperature, all fatigue data are shown to be capable of being reduced to a single reference curve at some temperature. Examples are given which demonstrate the capability of the fatigue failure criterion to predict failure of complex symmetrically balanced laminates from relevant parameters obtained from the observed behavior of unidirectional and angle-ply laminates.

Rotem, A.↗

A temperature dependent fatigue failure criterion for graphite/epoxy laminates

A fatigue failure criterion applicable to composite materials is developed and applied to predict the fatigue behavior of graphite/epoxy laminates with particular emphasis on the influence of temperature. Tensile stress-strain curves and tension-tension fatigue curves for various unidirectional, angle-ply and symmetrically balanced laminates were developed at test temperatures of 25 C, 74 C and 114 C. In general for most laminates a reduction in both static strength and fatigue strength is observed with increasing temperature. This reduction appeared more severe in fatigue loading than in static tensile loading and most severe where the shear stress in the lamina is the dominant failure mode. Through an analytical formulation of shifting functions for the influences of temperature, all fatigue data are shown to be capable of being reduced to a single reference curve at some temperature. Additionally, examples are given which demonstrate the capability of the fatigue failure criterion to predict failure of complex symmetrically balanced laminates from relevant parameters obtained from the observed behavior of unidirectional and angle-ply laminates.

Rotem, A.↗

Fatigue behavior of SiC reinforced Ti/6Al-4V/ at 650 C

Axial, low cycle fatigue properties of 25 and 44 fiber vol pct SiC/Ti(6Al-4V) composites, measured at 650 C, were compared with the fatigue properties of unreinforced Ti(6Al-4V) at the same temperature. A prior study of the fatigue behavior of this composite system at room temperature indicated that the SiC fiber reinforcement did not provide the anticipated improvement of fatigue resistance of this alloy. At 650 C, the composite fatigue properties degraded somewhat from those at room temperature. However, these properties degraded more for the unreinforced matrix at 650 C with the result that the composite fatigue strength was two to three times the fatigue strength of the matrix alloy. The reasons for this reversal are discussed in terms of crack initiation at broken fibers and residual matrix stresses.

Bhatt, R. T.↗