Fatigue crack growth in ultrafine grained aluminium alloy

The microstructure, fatigue crack growth behaviour and hardness of ultra fine grained 6061 aluminium alloy obtained by equal angle channel processing was studied. ECAP resulted in significant grain refinement down to the sub micron level and corresponding increase in hardness. Results point to a similar fatigue threshold stress intensity range and fatigue crack growth rates for 1, 2, 4 and 6 passes of ECAP.

Modelling of laser beam spot-weld using 2-D hybrid crack finite elements

Laser beam spot-welding is widely applied to join sheet metals for automotive components especially for thinsheet components in automotive industries. The spot welds in such metallic structures contribute a lot to the integrated strength and fatigue life for the whole structures and they are responsible for their damage or collapse in some loading cases. In this paper, the 2-D hybrid special finite elements each containing an edge crack are employed to study the fracture behaviors of laser beam spot-welds. Hence the calculation accuracy in the vicinity of crack tips is ensured, and a better description of stress singularity with only one hybrid element surrounding one crack is provided. The numerical modeling for laser beam spot-welds subjected to three typical modes ofloadings including tension-lap, shear-lap and angle-clip can be greatly simplified with the applications of such elements. Three specimens under lap-shear, lap-tension and angle clip are devised and analyzed respectively, and main fracture parameters such as stress intensity factors and the initial direction of crack growth are obtained through tinite element analyses. The computed results ti'om numerical examples demonstrate the validity and versatility of the proposed modeling.

Textural fractography of fatigue failures under variable cycle loading

A new concept of counting time at fatigue processes is proposed, aimed to reach fractographic compatibility in cases of different loading sequences. Values of cycle effectivity are summarized to give the new reference time. The improvement is shown in application - textural fractography of three specimens loaded by constant cycle, constant cycle with periodic overloading, and a random block, respectively. In contrast to the conventional crack growth rate, the reference crack growth rate is related to common morphologic features of all fracture surfaces.

Physical interpretation of the reference features in textural fractography of fatigue fractures

Reference features of a fatigue fracture surface are the reference texture and reference crack growth rate which are unambiguously mutually related. The reference texture is a subset of the image texture in SEM fractographs. It is expected to be common to all fractures caused by loadings in which significant events occur sufficiently regularly and frequently. The ratio of the reference and the conventional crack growth rate called reference factor is a characteristic of a particular loading. Its value may be related to the sequence of successive sizes of the cyclic plastic zone, while the mechanism of the effect of overloads follows the models of Wheeler and Willenborg. Application to a set of nine test specimens from aluminium alloy loaded by three different loading regimes is shown.

Phase and crystal orientation study of a TRansformation Induced Plasticity steel subjected to cyclic load induced fatigue

An electron backscatter diffraction (EBSD) study of the microstructure of TRIP steel during fatigue failure. Phase and crystal orientation study of a TRIP steel subjected to cyclic load induced fatigue. The relative fractions of austenite, ferrite and martensite are quantified within the strain field of a fatigue crack tip. This data is a subset of data supporting a wider study of the fatigue properties of multiphase steels used in the automotive industry. The different microstructural phases present in these steels can influence the strain life and cyclic stabilized strength of the material due to the way in which these phases accommodate the applied cyclic strain. Fully reversed strain-controlled low-cycle fatigue tests have been used to determine the mechanical fatigue performance of a dual-phase (DP) 590 and transformation induced plasticity (TRIP) 780 steel, with transmission electron microscopy (TEM) and scanning electron microscopy (SEM-EBSD) used to examine the deformed microstructures .

Numerical study of the mode I delamination toughness of Z-pinned laminates

A finite element (FE) model is developed to investigate mode I delamination toughness of z-pin reinforced composite laminates. The z-pin pullout process is simulated by the deformation of a set of non-linear springs. A critical crack opening displacement (COD) criterion is used to simulate crack growth in a double-cantilever-beam (DCB) made of z-pinned laminates. The toughness of the structure is quantified by the energy release rate, which is calculated using the contour integral method. The FE model is verified for both unpinned and z-pinned laminates. Predicted loading forces from FE analysis are compared to available test data. Good agreement is achieved. Our numerical results indicate that z-pins can greatly increase the mode I delamination toughness of the composite laminates. The influence of design parameters on the toughness enhancement of z-pinned laminates is also investigated, which provides important information to optimise and improve the z-pinning technique.

Mode II delamination toughness of Z-pinned laminates

Mode II delamination toughness of z-pin reinforced composite laminates is investigated using finite element (FE) method. The z-pin pullout process is simulated by the deformation and breakage of non-linear springs. A critical shear stress criterion based on linear elastic fracture mechanics is used to simulate crack growth in an end-notched-flexure (ENF) beam made of z-pinned laminates. The mode II toughness is quantified by the potential energy release rate calculated using the contour integral method. This FE model is verified for an unpinned ENF composite beam. Numerical results obtained indicate that z-pins can significantly increase the mode II delamination toughness of composite laminate. The effects of design variables on the toughness enhancement of z-pinned laminates are also studied, which provides an important technological base and useful data to optimize and improve the z-pinning technique.

Manufacturing influence on the delamination fracture behavior of the T800H/3900-2 carbon fiber reinforced polymer composites

'Torayca' T800H/3900-2 is the first material qualified on Boeing Material Specification (BMS 8-276) which utilizes the thermoplastic-particulate interlayer toughening technology. Two manufacturing processes, the autoclave process and the fast heating rated Quickstep™ process, were employed to cure this material. The Quickstep process is a unique composite production technology which utilizes the fast heat transfer rate of fluid to heat and cure polymer composite components. The manufacturing influence on the mode I delamination fracture toughness of laminates was investigated by performing double cantilever beam tests. The composite specimens fabricated by two processes exhibited dissimilar delamination resistance curves (R-curves) under mode I loading. The initial value of fracture toughness GIC-INIT was 564 J/m2 for the autoclave specimens and 527 J/m2 for the Quickstep specimens. However, the average propagation fracture toughness GIC-PROP was 783 J/m2 for the Quickstep specimens, which was 2.6 times of that for the autoclave specimens. The mechanism of fracture occurred during delamination was studied under scanning electron microscope (SEM). Three types of fracture were observed: the interlayer fracture, the interface fracture, and the intralaminar fracture. These three types of fracture played different roles in affecting the delamination resistance curves during the crack growth. More fiber bridging was found in the process of delamination for the Quickstep specimens. Better fiber/matrix adhesion was found in the Quickstep specimens by conducting indentation-debond tests.

Fracture analysis of spot-welds with edge cracks using 2-D hybrid special finite element

This paper employed a systematic analysis using a 2-D hybrid special finite element containing an edge crack in order to describe the fracture behavior of spot-welds in automotive structures. The 2-D hybrid special finite element is derived form a mixed formulation with a complex potential function with the description of the singularity of a stress field. The hybrid special finite element containing an edge crack can give a better description of its singularity with only one hybrid element surrounding one crack. The advantage of this special element is that it can greatly simplify the numerical modeling of the spot welds. Some numerical examples demonstrate the validity and versatility of the present analysis method. The lap-shear, lap-tension and angle-clip specimens are analyzed and some useful fracture parameters such as the stress intensity factor and the initial direction of crack growth are obtained simultaneously.