Influence of microstructure variability on short crack growth behavior

Fatigue life in metals is predicted utilizing regression analysis of large sets of experimental data, thus representing the material’s macroscopic response. Furthermore, a high variability in the short crack growth (SCG) rate has been observed in polycrystalline materials, in which the evolution and distributionof local plasticity is strongly influenced by the microstructure features. The present work serves to (a) identify the relationship between the crack driving force based on the local microstructure in the proximity of the crack-tip and (b) defines the correlation between scatter observed in the SCG rates to variability in the microstructure. A crystal plasticity model based on the fast Fourier transform formulation of the elasto-viscoplastic problem (CP-EVP-FFT) is used, since the ability to account for the both elastic and plastic regime is critical in fatigue. Fatigue is governed by slip irreversibility, resulting in crack growth, which starts to occur during local elasto-plastic transition. To investigate the effects of microstructure variability on the SCG rate, sets of different microstructure realizations are constructed, in which cracks of different length are introduced to mimic quasi-static SCG in engineering alloys. From these results, the behavior of the characteristic variables of different length scale are analyzed: (i) Von Mises stress fields (ii) resolved shear stress/strain in the pertinent slip systems, and (iii) slip accumulation/irreversibilities. Through fatigue indicator parameters (FIP), scatter within the SCG rates is related to variability in the microstructural features; the results demonstrate that this relationship between microstructure variability and uncertainty in fatigue behavior is critical for accurate fatigue life prediction.

Laser shock peening treatment to control and moderate fatigue crack growth in aircraft structure based on residual stress engineering approach

Laser Shock Peening (LSP) is a surface enhancement treatment which induces a significant layer of beneficial compressive residual stresses of up to several mm underneath the surface of metal components in order to improve the detrimental effects of the crack growth behavior rate in it. The aim of this thesis is to predict the crack growth behavior in metallic specimens with one or more stripes which define the compressive residual stress area induced by the Laser Shock Peening treatment. The process was applied as crack retardation stripes perpendicular to the crack propagation direction with the object of slowing down the crack when approaching the peened stripes. The finite element method has been applied to simulate the redistribution of stresses in a cracked model when it is subjected to a tension load and to a compressive residual stress field, and to evaluate the Stress Intensity Factor (SIF) in this condition. Finally, the Afgrow software is used to predict the crack growth behavior of the component following the Laser Shock Peening treatment and to detect the improvement in the fatigue life comparing it to the baseline specimen. An educational internship at the “Research & Technologies Germany – Hamburg” department of AIRBUS helped to achieve knowledge and experience to write this thesis. The main tasks of the thesis are the following: •To up to date Literature Survey related to “Laser Shock Peening in Metallic Structures” •To validate the FE model developed against experimental measurements at coupon level •To develop design of crack growth slowdown in Centered Cracked Tension specimens based on residual stress engineering approach using laser peened strip transversal to the crack path •To evaluate the Stress Intensity Factor values for Centered Cracked Tension specimens after the Laser Shock Peening treatment via Finite Element Analysis •To predict the crack growth behavior in Centered Cracked Tension specimens using as input the SIF values evaluated with the FE simulations •To validate the results by means of experimental tests

Influence of adhesive thickness on adhesively bonded joints under fatigue loading

Research on adhesive joints is arousing increasing interest in aerospace industry. Incomplete knowledge of fatigue in adhesively bonded joints is a major obstacle to their application. The prediction of the disbonding growth is yet an open question. This thesis researches the influence of the adhesive thickness on fatigue disbond growth. Experimental testing on specimens with different thickness has been performed. Both a conventional approach based on the strain energy release rate and an approach based on cyclic strain energy are provided. The inadequacy of the former approach is discussed. Outcomes from tests support the idea of correlating the crack growth rate to the cyclic strain energy. In order to push further the study, a 2D finite element model for the prediction of disbond growth under quasi-static loading has been developed and implemented in Abaqus. Numerical simulations have been conducted with different values of the adhesive thickness. The results from tests and simulations are in accordance with each other. According to them, no dependence of disbonding on the adhesive thickness has been evidenced.

Using sclerochronology to estimate the growth rate in Pinna nobilis: a case study of Les Alfaques Bay population (Ebro Delta, Spain).

Pinna nobilis is the biggest Mediterranean bivalve, endemic and semi-infaunal. Provide hard substrates to colonize, increasing the spatial heterogeneity of the softbottom communities. P. nobilis suffer a drastic decline due to the anthropogenic pressures. It’s included in the Habitats Directive, in the Barcelona Convention, and in the red lists of many Mediterranean countries. Estimates the growth rate allows to understand the population dynamics of species and yield knowledge to improve protection efforts. In this study a new methodology based on sclerochronology was used to estimate the age and the growth rate of a P. nobilis population located in Les Alfaques bay. The shells of 35 specimens were cataloged. A subsample of 20 individuals was selected, and one valve of each specimens was cut into radial sections along PAMS (Posterior Adductor Muscle Scar) to study the inner register. Thus, the positions of PAMS obscured by nacre were identified, and the number of missing records was estimated by the width of the calcitic layer in the anterior part of the shell. The first growth curve for the Les Alfaques bay population was calculated from the length/age data. To simulate the growth rate of this population, the growth model based on the modified Von Bertalanffy equation was used. Shallow water usually hosts small sized populations of P. nobilis, while in deeper waters specimens reaches larger size. In Les Alfaques bay the population is composed by large size individuals though it’s located in shallows waters. This unusual size pattern is probably due to a sand bar that offers protection from hydrodynamic stress, allowing individuals to elongate more. This study contributes to the knowledge on P. nobilis biology and, with the aim to monitor this species, the growth curve could be used as baseline for future studies on habitat characteristics that may affect the population structure and dynamics in Les Alfaques Bay.

L'effetto della pressione sulle perdite in condotte con fessure longitudinali - The effect of pressure on leakage in longitudinally crecked pressurized pipes.

La crescente attenzione verso un utilizzo attento, sostenibile ed economicamente efficiente della risorsa idrica rende di primaria importanza il tema delle perdite idriche e della gestione efficiente dei sistemi idrici. La richiesta di controlli dell’uso dell’acqua è stata avanzata a livello mondiale. Il problema delle perdite idriche nei Paesi industrializzati è stato così affrontato con specifiche normative e procedure di best practice gestionale per avanzare una valutazione delle perdite idriche e una limitazione degli sprechi e degli usi impropri. In quest’ambito, la pressione gioca un ruolo fondamentale nella regolazione delle perdite reali. La regolazione delle pressioni nelle diverse ore del giorno consente, infatti, di poter agire su queste ultime perdite, che aumentano all’aumentare della pressione secondo una cosiddetta legge di potenza. La motivazione della presente tesi è originata dalla necessità di quantificare il livello di perdita idrica in un sistema acquedottistico in relazione alla pressione all’interno del sistema stesso. Per avere una stima realistica che vada al di là della legge della foronomia, si vuole valutare l’influenza della deformabilità della condotta in pressione fessurata sull’entità delle perdite idriche, con particolare attenzione alle fessurazioni di tipo longitudinale. Tale studio è condotto tramite l’introduzione di un semplice modello di trave alla Winkler grazie al quale, attraverso un’analisi elastica, si descrive il comportamento di una generica condotta fessurata longitudinalmente e si valuta la quantità d’acqua perduta. I risultati ottenuti in condizioni specifiche della condotta (tipo di materiale, caratteristiche geometriche dei tubi e delle fessure, etc.) e mediante l’inserimento di opportuni parametri nel modello, calibrati sui risultati forniti da una raffinata modellazione tridimensionale agli elementi finiti delle medesime condotte, verranno poi confrontati con i risultati di alcune campagne sperimentali. Gli obiettivi del presente lavoro sono, quindi, la descrizione e la valutazione del modello di trave introdotto, per stabilire se esso, nonostante la sua semplicità, sia effettivamente in grado di riprodurre, in maniera realistica, la situazione che si potrebbe verificare nel caso di tubo fessurato longitudinalmente e di fornire risultati attendibili per lo studio delle perdite idriche. Nella prima parte verrà approfondito il problema della perdite idriche. Nella seconda parte si illustrerà il semplice modello di trave su suolo elastico adottato per l’analisi delle condotte in pressione fessurate, dopo alcuni cenni teorici ai quali si è fatto riferimento per la realizzazione del modello stesso. Successivamente, nella terza parte, si procederà alla calibrazione del modello, tramite il confronto con i risultati forniti da un’analisi tridimensionale agli elementi finiti. Infine nella quarta parte verrà ricavata la relazione flusso-pressione con particolare attenzione all’esponente di perdita, il cui valore risulterà superiore a quello predetto dalla teoria della foronomia, e verrà verificata l’effettiva validità del modello tramite un confronto con i risultati sperimentali di cui è stata fatta menzione in precedenza.

Evolution of the structural and fracture design of the ISS payloads due to the new launchers, specifically applied to Biolab IEC-2 projects

The relatively young discipline of astronautics represents one of the scientifically most fascinating and technologically advanced achievements of our time. The human exploration in space does not offer only extraordinary research possibilities but also demands high requirements from man and technology. The space environment provides a lot of attractive experimental tools towards the understanding of fundamental mechanism in natural sciences. It has been shown that especially reduced gravity and elevated radiation, two distinctive factors in space, influence the behavior of biological systems significantly. For this reason one of the key objectives on board of an earth orbiting laboratory is the research in the field of life sciences, covering the broad range from botany, human physiology and crew health up to biotechnology. The Columbus Module is the only European low gravity platform that allows researchers to perform ambitious experiments in a continuous time frame up to several months. Biolab is part of the initial outfitting of the Columbus Laboratory; it is a multi-user facility supporting research in the field of biology, e.g. effect of microgravity and space radiation on cell cultures, micro-organisms, small plants and small invertebrates. The Biolab IEC are projects designed to work in the automatic part of Biolab. In this moment in the TO-53 department of Airbus Defence & Space (formerly Astrium) there are two experiments that are in phase C/D of the development and they are the subject of this thesis: CELLRAD and CYTOSKELETON. They will be launched in soft configuration, that means packed inside a block of foam that has the task to reduce the launch loads on the payload. Until 10 years ago the payloads which were launched in soft configuration were supposed to be structural safe by themselves and a specific structural analysis could be waived on them; with the opening of the launchers market to private companies (that are not under the direct control of the international space agencies), the requirements on the verifications of payloads are changed and they have become much more conservative. In 2012 a new random environment has been introduced due to the new Space-X launch specification that results to be particularly challenging for the soft launched payloads. The last ESA specification requires to perform structural analysis on the payload for combined loads (random vibration, quasi-steady acceleration and pressure). The aim of this thesis is to create FEM models able to reproduce the launch configuration and to verify that all the margins of safety are positive and to show how they change because of the new Space-X random environment. In case the results are negative, improved design solution are implemented. Based on the FEM result a study of the joins has been carried out and, when needed, a crack growth analysis has been performed.

Measurement of LSP-induced residual stresses and fatigue life on thin-walled aluminium alloys specimens

This thesis work encloses activities carried out in the Laser Center of the Polytechnic University of Madrid and the laboratories of the University of Bologna in Forlì. This thesis focuses on the superficial mechanical treatment for metallic materials called Laser Shock Peening (LSP). This process is a surface enhancement treatment which induces a significant layer of beneficial compressive residual stresses underneath the surface of metal components in order to improve the detrimental effects of the crack growth behavior rate in it. The innovation aspect of this work is the LSP application to specimens with extremely low thickness. In particular, after a bibliographic study and comparison with the main treatments used for the same purposes, this work analyzes the physics of the operation of a laser, its interaction with the surface of the material and the generation of the surface residual stresses which are fundamentals to obtain the LSP benefits. In particular this thesis work regards the application of this treatment to some Al2024-T351 specimens with low thickness. Among the improvements that can be obtained performing this operation, the most important in the aeronautic field is the fatigue life improvement of the treated components. As demonstrated in this work, a well-done LSP treatment can slow down the progress of the defects in the material that could lead to sudden failure of the structure. A part of this thesis is the simulation of this phenomenon using the program AFGROW, with which have been analyzed different geometric configurations of the treatment, verifying which was better for large panels of typical aeronautical interest. The core of the LSP process are the residual stresses that are induced on the material by the interaction with the laser light, these can be simulated with the finite elements but it is essential to verify and measure them experimentally. In the thesis are introduced the main methods for the detection of those stresses, they can be mechanical or by diffraction. In particular, will be described the principles and the detailed realization method of the Hole Drilling measure and an introduction of the X-ray Diffraction; then will be presented the results I obtained with both techniques. In addition to these two measurement techniques will also be introduced Neutron Diffraction method. The last part refers to the experimental tests of the fatigue life of the specimens, with a detailed description of the apparatus and the procedure used from the initial specimen preparation to the fatigue test with the press. Then the obtained results are exposed and discussed.