Considerations about the welding repair effects on the structural integrity of an airframe critical to the flight-safety

Structures critical to the flight-safety are commonly submitted to several maintenance repairs at the welded joints in order to prolong the in-service life of aircrafts. The aim of this study is to analyze the effects of Tungsten Inert Gas (TIG) welding repair on the structural integrity of the AISI 4130 aeronautical steel by means of experimental fatigue crack growth tests in base-material, heat-affected zone (HAZ) and weld metal. The tests were performed on hot-rolled steel plate specimens, 0.89 mm thick, with load ratio R = 0.1, constant amplitude, at 10 Hz frequency and room temperature. Increase of the fracture resistance was observed in the weld metal but decreasing in the HAZ after repair. The results were associated to microhardness and microstructural changes with the welding sequence. (C) 2010 Published by Elsevier Ltd.

Determinação da taxa de propagação de trinca por fadiga dos aços SAE-1050 e SAE-4130 empregados na fabricação de eixos ferroviários

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Fractografia quantitativa de superfícies obtidas em ensaios de propagação de trincas por fadiga em aço inoxidável 15 –5PH

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Fractografia quantitativa: análise do comportamento fractal da fratura por explosão hidrostática em cilindros de aço sem costura

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Polymer Matrix-Based Piezoelectric Composite for Structural Health Monitoring

Structural health monitoring (SHM) refers to the procedure of assessing the structure conditions continuously so it is an alternative to conventional nondestructive evaluation (NDE) techniques [1]. With the growing developments in sensor technology acoustic emission (AE) technology has been attracting attention in SHM applications. AE are characterized by waves produced by the sudden internal stress redistribution caused by the changes in the internal structure, such as fatigue, crack growth, corrosion, etc. Piezoelectric materials such as Lead Zirconate Titanate (PZT) ceramic have been widely used as sensor due to its high electromechanical coupling factor and piezoelectric d coefficients. Because of the poor mechanical characteristic and the lack in the formability of the ceramic, polymer matrix-based piezoelectric composites have been studied in the last decade in order to obtain better properties in comparison with a single phase material. In this study a composite film made of polyurethane (PU) and PZT ceramic particles partially recovered with polyaniline (PAni) was characterized and used as sensor for AE detection. Preliminary results indicate that the presence of a semiconductor polymer (PAni) recovering the ceramic particles, make the poling process easier and less time consuming. Also, it is possible to observe that there is a great potential to use such type of composite as sensor for structure health monitoring.

Avaliação da integridade estrutural em um tubo de aço API 5L X70 através da propagação de trincas por fadiga

Pós-graduação em Engenharia Mecânica - FEG

Estudo do comportamento em fadiga de uma chapa de aço microligado, grau API 5L X70

In engineering, for correct designing the structural components required for cyclical stresses, it is necessary to determine a limit of resistance to fatigue, which is the maximum amplitude of the applied tension under which the fatigue failure does not occurs after a certain number cycles. The marine environment is hostile, not only by the high pressure, corrosion, but also by low temperatures. Petrol Production units, composed of the risers (pipelines connecting the oil well to the ship), are dimensioned to remain installed for periods of 20 up to 30 years, and must therefore be prepared to support various efforts, such as tidal, wind currents and everything that is related. This paper focuses on a study on the fatigue behavior of microalloyed steel, API 5L Grade X70, used to transport oil and gas by pipelines. For analysis, we obtained the curves S-N (stress vs. number of cycles) using laboratory data collected from cylindrical longitudinal and transverse specimens used in axial fatigue test in accordance with ASTM E466. The tensile tests and microhardness were performed to characterize the mechanical properties of the samples, and it was found that the values meet the specifications of the standard API 5L. To characterize microstructurally the material, it was also made a metallographic analysis of the steel under study, and the origin of the fatigue crack was investigated with the support of a scanning electron microscope (SEM).

Estudo da propagação de trinca por fadiga sob carregamento de amplitude variável

For engineering projects that require high reliability levels, is often not enough know only physical and chemical material properties. It’s necessary understand the failure mode of these materials in operation to ensure security level in the project and establish more stringent criteria in the analysis of structural integrity. Due to this need, aircraft industry has been using aluminum alloys in their designs and projects. “Currently more than 70% of aircraft structures are built of high strength aluminum alloys among which stand out 7075-T6 and 2024-T3 alloys, which are considered basics for being used in the new alloys development.” (PASTOUKHOV & VOORWALD, 1995). Some years ago ALCOA develops Al 2524 alloy that has emerged as refinement of Al 2024 (Al, Cu. Mg) alloy, with purpose of improve fracture toughness and fatigue resistance on structural components. The present research addresses testing of fatigue crack propagation under variable amplitude loading for Al 2024 alloy, observing the interaction effects from application of overhead blocks and plastic zone at the crack tip and makes an analysis of fracture surface images

Caracterização microestrutural de junta soldada com arco submerso e análise da propagação de trincas em um tubo de aço API X 70

In this work a study of an API 5L X70 steel, which is used in the manufacture of oil and gas pipelines, has been made. This class of steel show high strength and ductility values, and has been increasingly studied due the growing demand of oil and natural gas, which in consequence, increases the needing of new pipelines to transport them. The material studied has been directly taken from a tube provided by TenarisConfab, and a special attention has been given to the fatigue crack growth rate study, which proved that a crack will grow at different rates according to the tube position where it is growing

Estudo do efeito do processo de shot peening na taxa de propagação de trinca por fadiga na liga aeronáutica 2024 - T3

Pós-graduação em Engenharia Mecânica - FEG

Evaluation of WC-10Ni thermal spray coating with shot peening on the fatigue strength of AISI 4340 steel

Fatigue failure is a result of a crack initiation and propagation, in consequence of a cyclical load. In aeronautical components as landing gear the fatigue strength is an important parameter to be considered in project, as well as the corrosion and wear resistance.The thermal sprayed HVOF technology it's normally used to protect components against wear and corrosion, and are being considerate an alternative to replace chromium by the aeronautical industry. With respect to fatigue life, the HVOF technique induces residual stress on the interface. In the case of tensile residual stresses, the initiation and propagation phases of fatigue process are accelerated; on the other hand, compressive residual stresses close to the surface may increase fatigue life. The technique to improve the coated materials fatigue strength is the shot peening process, which induces residual stress in the surface in order to delay the nucleation and propagation process.The aim of present study is to compare the influence of WC-10 Ni coating applied by HVOF on the fatigue strength of AISI 4340 steel, with and without shot peening. S-N curves were obtained in axial fatigue tests for material base, and tungsten carbide coated specimens. (C) 2010 Published by Elsevier Ltd.

Influence of shot peening and hard chromium electroplating on the fatigue strength of 7050-T7451 aluminum alloy

Chromium electrodeposition is a technique for the production of functional coatings on engineering components. These coatings are extensively micro-cracked and present high level of hardness, resistance to corrosion and wear and low coefficient of friction. In this paper the shot peening influence on the fatigue strength of aluminum 7050-T7451 alloy chromium electroplated, was investigated.The shot peening process was carried out to create residual stresses using ceramic and glass shots. A hard chromium electroplated coating of 100 mu m thickness was performed on the base material and the shot peened base material surfaces. S-N curves were obtained in axial and bending fatigue tests and compared with the 7050-T7451 aluminum alloy. In order to study the influence of residual stresses on fatigue life, the behavior of compressive residual stress field was measured by an X-ray tensometry.An increase in the axial fatigue strength of 25% and 50% of ceramic and glass shots, respectively, was observed. The lower performance in fatigue life for ceramic-shot peening may be attributed to higher surface damage, as a consequence of the overpeening intensity performed. However, in bending fatigue the behavior was practically equivalent for both processes. Fracture surface analysis by scanning electron microscopy was used to observe crack origin sites from shot peened and chromium electroplated samples. (C) 2006 Elsevier Ltd. All rights reserved.

Effect of electroless nickel interlayer on the fatigue strength of chromium electroplated AISI 4340 steel

Deposition of wear-resistant hard chromium plating leads to a decrease in the fatigue strength of the base material. Despite the effective protection against wear and corrosion, fatigue life and environmental requirements result in pressure to identify alternatives or to improve conventional chromium electroplating mechanical characteristics. An interesting, environmentally safer and cleaner alternative for the replacement of hard chronic plating is tungsten carbide thermal spray coating, applied by high velocity oxyfuel (HVOF) process.To improve the fatigue strength of aeronautical steel chromium electroplated, shot peening is a successfully used method. Multiple lacer systems of coatings are considered to have larger resistance to crack propagation in comparison with simple layer.The aim of this study was to analyze the effect of nickel underplate on the fatigue strength of hard chromium plated AISI 4340 steel in two mechanical conditions: HRc 39 and HRc 52.Rotating bending fatigue tests results indicate that the clectroless nickel plating underlayer is responsible for the increase in fatigue strength of AISI 4340 steel chromium electroplated. This behavior may be attributed to the largest toughness/ductility and compressive residual stresses which, probably, arrested or delayed the inicrocrack propagation from the hard chromium external layer. The compressive residual stress field (CRSF) induced by the electroplating process was determined by X-ray diffraction method. The evolution of fatigue strength compressive residual stress field CRSF and crack sources are discussed and analyzed by SEM. (c) 2006 Elsevier Ltd. All rights reserved.

Improvement in the fatigue strength of chromium electroplated AISI 4340 steel by shot peening

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)