An experimental approach for non-destructive evaluation of fatigue damage in CFRP composites

Study of fatigue phenomenon in composites requires a dynamic tool which can detect and identify different failure mechanisms involved. The tool should also be capable of monitoring the cumulative damage progression on-line. Acoustic Emission Technique has been utilized in the experimental investigations on unidirectional carbon fiber reinforced plastic (CFRP) composite specimens subjected to tension-tension fatigue. Amplitude as well as frequency distribution of Acoustic Emission (AE) signals have been studied to detect and characterize different failure mechanisms. For a quantitative measure of degradation of the material with fatigue load cycles, reduction in stiffness of the specimen has been measured intermittently. Ultrasonic imaging could give the information on the changes in the interior status of the material at different stages of fatigue life.

Fatigue damage assessment in cracked RC beams

In this work, an attempt has been made to assess the fatigue life of reinforced concrete beams, by proposing a crack propagation law which accounts for parameters such as fracture toughness, crack length, loading ratio and structural size. A numerical procedure is developed to compute fatigue life of RC beams. The predicted results are compared with the available experimental data in the literature and seen to agree reasonably well. Further, in order to assess the remaining life of an RC member, the moment carrying capacity is determined as a function of crack extension, based on the crack tip opening displacement and residual strength of the member is computed at an event of unstable fracture.

A thermodynamic correlation between damage and fracture as applied to concrete fatigue

Fatigue damage in concrete is characterized by the simultaneous presence of micro and macrocracks. The theory of fracture mechanics conveniently handles the propagation of macrocracks, whereas damage mechanics precisely describes the state of microcracking. This paper provides a platform to correlate fracture mechanics and damage mechanics theories through an energy equivalence within a thermodynamic framework by equating the energy dissipated according to each theory. Through this correlation, damage corresponding to a given crack length could be obtained, and alternatively a discrete crack could be transformed into an equivalent damage zone. The results are validated using available experimental data on concrete fatigue including stiffness degradation and acoustic emission. (C) 2015 Elsevier Ltd. All rights reserved.

A thermodynamic correlation between damage and fracture as applied to concrete fatigue

Fatigue damage in concrete is characterized by the simultaneous presence of micro and macrocracics. The theory of fracture mechanics conveniently handles the propagation of macrocracks, whereas damage mechanics precisely describes the state of microcracking. This paper provides a platform to correlate fracture mechanics and damage mechanics theories through an energy equivalence within a thermodynamic framework by equating the energy dissipated according to each theory. Through this correlation, damage corresponding to a given crack length could be obtained, and alternatively a discrete crack could be transformed into an equivalent damage zone. The results are validated using available experimental data on concrete fatigue including stiffness degradation and acoustic emission. (C) 2015 Elsevier Ltd. All rights reserved.

A comparative study of failure features in aerospace grade unidirectional and bidirectional woven CFRP composite laminates under four-point bend fatigue loads

Damage mechanisms in unidirectional (UD) and bi-directional (BD) woven carbon fiber reinforced polymer (CFRP) laminates subjected to four point flexure, both in static and fatigue loadings, were studied. The damage progression in composites was monitored by observing the slopes of the load vs. deflection data that represent the stiffness of the given specimen geometry over a number of cycles. It was observed that the unidirectional composites exhibit gradual loss in stiffness whereas the bidirectional woven composites show a relatively quicker loss during stage II of fatigue damage progression. Both, the static and the fatigue failures in unidirectional carbon fiber reinforced polymer composites originates due to generation of cracks on compression face while in bidirectional woven composites the damage ensues from both the compression and the tensile faces. These observations are supported by a detailed fractographic analysis.

Aircraft Composite Structure Preventive Maintenance

In this paper, a methodology to reduce composite structure maintenance operational cost using SHM systems is adressed. Based on SHM real-time data, in-service structure lifetime prognostic and remaining useful lifetime (RUL) can be performed. Maintenance timetable can be therefore predicted by optimizing inspection times. A probabilistic ap-proach is combined with phenomenological fatigue damage models for composite mate-rials to perform maintenance cost-effectiveness of composite structure. A Monte Carlo method is used to estimate the probability of failure of composite structures and com-pute the average number of composite structure components to be replaced over the component lifetime. The replacement frequency of a given structure component over the aircraft lifetime is assessed. A first application of aeronautical composite structure maintenance is considered. Two composite models to predict the fatigue life and several laminates have been used. Our study shows that maintenance cost-effectiveness depends on material and fatigue loading applied.

A thermodynamic framework for the evolution of damage in concrete under fatigue

A closed-form expression for the dual of dissipation potential is derived within the framework of irreversible thermodynamics using the principles of dimensional analysis and self-similarity. Through this potential, a damage evolution law is proposed for concrete under fatigue loading using the concepts of damage mechanics in conjunction with fracture mechanics. The proposed law is used to compute damage in a volume element when a member is subjected to fatigue loading. The evolution of damage from microcracking to macrocracking of the entire member is captured through a series of volume elements failing one after the other. The number of loading cycles to failure of the member is obtained as the summation of number of cycles to failure for each individual volume element. A parametric study is conducted to determine the effect of the size of the volume element on the model's prediction of fatigue life. A global damage index is also defined, and the residual moment carrying capacity of damaged beams is evaluated. Through a deterministic sensitivity analysis, it is found that the load range and maximum aggregate size are the most influencing parameters on the fatigue life of a plain concrete beam.

Fatigue Laws Via Functional Equations

In routine industrial design, fatigue life estimation is largely based on S-N curves and ad hoc cycle counting algorithms used with Miner's rule for predicting life under complex loading. However, there are well known deficiencies of the conventional approach. Of the many cumulative damage rules that have been proposed, Manson's Double Linear Damage Rule (DLDR) has been the most successful. Here we follow up, through comparisons with experimental data from many sources, on a new approach to empirical fatigue life estimation (A Constructive Empirical Theory for Metal Fatigue Under Block Cyclic Loading', Proceedings of the Royal Society A, in press). The basic modeling approach is first described: it depends on enforcing mathematical consistency between predictions of simple empirical models that include indeterminate functional forms, and published fatigue data from handbooks. This consistency is enforced through setting up and (with luck) solving a functional equation with three independent variables and six unknown functions. The model, after eliminating or identifying various parameters, retains three fitted parameters; for the experimental data available, one of these may be set to zero. On comparison against data from several different sources, with two fitted parameters, we find that our model works about as well as the DLDR and much better than Miner's rule. We finally discuss some ways in which the model might be used, beyond the scope of the DLDR.

Prediction of fatigue strength in plain and reinforced concrete beams

A fatigue crack propagation model for concrete is proposed based on the concepts of fracture mechanics. This model takes into account the loading history, frequency of applied load, and size, effect parameters. Using this model, a method is described based on linear elastic fracture mechanics to assess the residual strength of cracked plain and reinforced concrete (RC) beams. This could be used to predict the residual strength (load carrying capacity) of cracked or damaged plain and reinforced concrete beams at a given level of damage. It has been seen that the fatigue crack propagation rate increases as. the size of plain concrete, beam increases indicating an increase in brittleness. In reinforced concrete (RC) beams, the fracture process becomes stable only when the beam is sufficiently reinforced.

Damage mechanisms in stainless steel and chromium carbide coatings under controlled environment fretting conditions

Fretting is of a serious concern in many industrial components, specifically, in nuclear industry for the safe and reliable operation of various component and/or system. Under fretting condition small amplitude oscillations induce surface degradation in the form of surface cracks and/or surface wear. Comprehensive experimental studies have been carried out simulating different fretting regimes under ambient and vacuum (10(-9) MPa) conditions and, temperature up to 400 degrees C. Studies have been carried out with stainless steel spheres on stainless steel flats, and stainless steel spheres against chromium carbide, with 25% nickel chrome binder coatings. Mechanical responses are correlated with the damage observed. It has been observed that adhesion plays a vital role in material degradation process, and its effectiveness depends on mechanical variables such as normal load, interfacial tangential displacement, characteristics of the contacting bodies and most importantly on the environment conditions. Material degradation mechanism for ductile materials involved severe plastic deformation, which results in the initiation or nucleation of cracks. Ratcheting has been observed as the governing damage mode for crack nucleation under cyclic tangential loading condition. Further, propagation of the cracks has been observed under fatigue and their orientation has been observed to be governed by the contact conditions prevailing at the contact interface. Coated surfaces show damage in the form of brittle fracture and spalling of the coatings. Existence of stick slip has been observed under high normal load and low displacement amplitude. It has also been observed that adhesion at the contact interface and instantaneous cohesive strength of the contacting bodies dictates the occurrence of material transfer. The paper discusses the mechanics and mechanisms involved in fretting damage under controlled environment conditions. (C) 2015 Elsevier B.V. All rights reserved.

Prediction of Fatigue Life in Plain Concrete Using Entropy Production

An energy approach within the framework of thermodynamics is used to model the fatigue process in plain concrete. Fatigue crack growth is an irreversible process associated with an irreversible entropy gain. A closed-form expression for entropy generated during fatigue in terms of energy dissipated is derived using principles of dimensional analysis and self-similarity. An increase in compliance is considered as a measure of damage accumulated during fatigue. The entropy at final fatigue failure is shown to be independent of loading and geometry and is proposed as a material property. A relationship between energy dissipated and number of cycles of fatigue loading is obtained. (C) 2015 American Society of Civil Engineers.

Wave propagation in elastic solids undergoing damage and growth process

Modeling and analysis of wave propagation in elastic solids undergoing damage and growth process are reported in this paper. Two types of diagnostic problems, (1) the propagation of waves in the presence of a slow growth process and (2) the propagation of waves in the presence of a fast growth process, are considered. The proposed model employs a slow and a fast time scale and a homogenization technique in the wavelength scale. A detailed analysis of wave dispersion is carried out. A spectral analysis reveals certain low-frequency bands, where the interaction between the wave and the growth process produces acoustic metamaterial-like behavior. Various practical issues in designing an efficient method of acousto-ultrasonic wave based diagnostics of the growth process are discussed. Diagnostics of isotropic damage in a ductile or quasi-brittle solid by using a micro-second pulsating signal is considered for computer simulations, which is to illustrate the practical application of the proposed modeling and analysis. The simulated results explain how an estimate of signal spreading can be effectively employed to detect the presence of a steady-state damage or the saturation of a process.

Damage assessment of basaltic rock mass due to repeated blasting in a railway tunnelling project - A case study

The demand for tunnelling and underground space creation is rapidly growing due to the requirement of civil infrastructure projects and urbanisation. Blasting remains the most inexpensive method of underground excavations in hard rock. Unfortunately, there are no specific safety guidelines available for the blasted tunnels with regards to the threshold limits of vibrations caused by repeated blasting activity in the close proximity. This paper presents the results of a comprehensive study conducted to find out the effect of repeated blast loading on the damage experienced by jointed basaltic rock mass during tunnelling works. Conducting of multiple rounds of blasts for various civil excavations in a railway tunnel imparted repeated loading on rock mass of sidewall and roof of the tunnel. The blast induced damage was assessed by using vibration attenuation equations of charge weight scaling law and measured by borehole extensometers and borehole camera. Ground vibrations of each blasting round were also monitored by triaxial geophones installed near the borehole extensometers. The peak particle velocity (V-max) observations and plastic deformations from borehole extensometers were used to develop a site specific damage model. The study reveals that repeated dynamic loading imparted on the exposed tunnel from subsequent blasts, in the vicinity, resulted in rock mass damage at lesser vibration levels than the critical peak particle velocity (V-cr). It was found that, the repeated blast loading resulted in the near-field damage due to high frequency waves and far-field damage due to low frequency waves. The far field damage, after 45-50 occurrences of blast loading, was up to 55% of the near-field damage in basaltic rock mass. The findings of the study clearly indicate that the phenomena of repeated blasting with respect to number of cycles of loading should be taken into consideration for proper assessment of blast induced damage in underground excavations.

High temperature time-dependent low cycle fatigue behaviour of a type 316L(N) stainless steel

Total strain controlled low cycle fatigue tests on 316L(N) stainless steel have been conducted in air at various strain rates in the temperature range of 773-873 K to identify the operative time-dependent mechanisms and to understand their influence on the cyclic deformation and fracture behaviour of the alloy. The cyclic stress response at all the testing conditions was marked by an initial hardening followed by stress saturation. A negative strain rate stress response is observed under specific testing conditions which is attributed to dynamic strain ageing (DSA). Transmission electron microscopy studies reveal that there is an increase in the dislocation density and enhanced slip planarity in the DSA regime. Fatigue life is found to decrease with a decrease in strain rate. The degradation in fatigue resistance is attributed to the detrimental effects associated with DSA and oxidation. Quantitative measurement of secondary cracks indicate that both transgranular and intergranular cracking are accelerated predominantly under conditions conducive to DSA.