Fatigue cracking from stress concentration in mild steel

Pulsating; tension fatigue tests have been carried out on edge notched specimens of a mild steel. An electrical potential drop technique was used to determine the number of cycles taken to initiate cracks and the rate at which the cracks grew across the specimen. The results could be described by the range of stress intensity factor, which for crack initiation was modified to take account of the notch root radius. Analysis of elastic stress distributions at cracks and notches and models of plasticity at crack tips are used to discuss the results. Limited evidence in the literature indicates that the fracture mechanics approach may provide a general description of crack initiation and growth in notched specimens, and a simple graphical method of calculating fatigue lives is described. The results are used to illustrate the effects of specimen size and geometry on the fatigue life of notched specimens. The relevance of the work to the assessment of the significance of defects in welds is discussed.

Planar variations in normal anisotropy in mild steel strip

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The copper cladding of steel by the submerged arc welding method

The literature available on submerged arc welding of copper and copper alloys, submerged arc welding with strip electrodes, and related areas has been reviewed in depth. Copper cladding of mild steel substrates by deposition from strip electrodes using the submerged arc welding process has been successful. A wide range of parameters, and several fluxes have been investigated. The range of deposit compositions is 66.4% Cu to 95.7% Cu. The weld beads have been metallographically examined using optical and electron microscopy. Equating weld beads to a thermodynamical equivalent of iron has proven to be an accurate and simplified means of handling quantitative data for multicomponent welds. Empirical equations derived using theoretical considerations characterize the weld bead dimensions as functions of the welding parameters and hence composition. The melting rate for strip electrodes is dependent upon the current-voltage product. Weld nugget size is increased by increased thermal transfer efficiencies resulting from stirring which is current dependent. The presence of Fe2O3 in a flux has been demonstrated to diminish electrode melting rate and drastically increase penetration, making flux choice the prime consideration in cladding operations. A theoretical model for welding with strip electrodes and the submerged arc process is presented.

Vibration in electromagnetically heated steel

When a ferromagnetic steel billet was heated by induction a large increase in the amplitude of longitudinal vibration frequently occurred as a result of resonance. This happened when a natural frequency of the bar coincided with twice the heating frequency or multiples thereof. The temperature at which resonance occurred depended on a number of factors including billet length and heating power. Resonance was most often observed when the surface temperature of the billet reached the Curie point. It is well established that magnetostrictive vibrations occur in a ferromagnetic material subjected to an alternating electromagnetic field, but existing data suggests that linear magnetostriction decreases towards the Curie point. Linear magnetostriction was measured in a sample of mild steel up to 800ºC using a high temperature strain gauge. The magnetostriction constant 100 was calculated assuming an average grain orientation in mild steel. The data was found to be comparable to that published for single crystals of iron. It was discovered that linear magnetostriction was responsible for resonance below 600ºC but not for temperatures near the Curie point. Other possible causes of resonance such as forces produced by the interaction between eddy currents and the alternating electromagnetic field, the alpha to gamma phase transformation and the existence of a thin ferromagnetic layer were investigated. None were found to account for resonance in bars of mild steel heated by induction. Experimental work relating to the induction heating of steel is compared to previous work on the subject of electromagnetic generation of ultrasound where a similar increase of the amplitude of longitudinal waves in steel is reported at the Curie point. It is concluded that the two phenomena are related as they show strong similarities.

An investigation of the mechanics of wire drawing with the superposition of an oscillatory drawing stress

A number of investigators have studied the application of oscillatory energy to a metal undergoing plastic deformation. Their results have shown that oscillatory stresses reduce both the stress required to initiate plastic deformation and the friction forces between the tool and workpiece. The first two sections in this thesis discuss historically and technically the devolopment of the use of oscillatory energy techniques to aid metal forming with particular reference to wire drawing. The remainder of the thesis discusses the research undertaken to study the effect of applying longitudinal oscillations to wire drawing. Oscillations were supplied from an electric hydraulic vibrator at frequencies in the range 25 to 500 c/s., and drawing tests were performed at drawing speeds up to 50 ft/m. on a 2000 lbf. bull-block. Equipment was designed to measure the drawing force, drawing torque, amplitude of die and drum oscillation and drawing speed. Reasons are given for selecting mild steel, pure and hard aluminium, stainless steel and hard copper as the materials to be drawn, and the experimental procedure and calibration of measuring equipment arc described. Results show that when oscillatory stresses are applied at frequencies within the range investigated : (a) There is no reduction in the maximum drawing load. (b) Using sodium stearate lubricant there is a negligible reduction in the coefficient of friction between the die and wire. (c) Pure aluminium does not absorb sufficient oscillatory energy to ease the movement of dislocations. (d) Hard aluminium is not softened by oscillatory energy accelerating the diffusion process. (e) Hard copper is not cyclically softened. A vibration analysis of the bull-block and wire showed that oscillatory drawiing in this frequency range, is a mechanical process of straining; and unstraining the drawn wire, and is dependent upon the stiffness of the material being drawn and the drawing machine. Directions which further work should take are suggested.

The Mechanics of the drawing of polygonal sections from round at elevated temperature

Economic factors such as the rise in cost of raw materials, labour and power, are compelling manufacturers of cold-drawn polygonal sections, to seek new production routes which will enable the expansion in the varieties of metals used and the inclusion of difficult-to-draw materials. One such method generating considerable industrial interest is the drawing of polygonal sections from round at elevated temperature. The technique of drawing mild steel, medium carbon steel and boron steel wire into octagonal, hexagonal and square sections from round at up to 850 deg C and 50% reduction of area in one pass has been established. The main objective was to provide a basic understanding of the process, with particular emphasis being placed on modelling using both experimental and theoretical considerations. Elevated temperature stress-strain data was obtained using a modified torsion testing machine. Data were used in the upper bound solution derived and solved numerically to predict drawing stress strain, strain-rate, temperature and flow stress distribution in the deforming zone for a range of variables. The success of this warm working process will, of course, depend on the use of a satisfactory elevated temperature lubricant, an efficient cooling system, a suitable tool material having good wear and thermal shock resistance and an efficient die profile design which incorporates the principle of least work. The merits and demerits of die materials such as tungsten carbide, chromium carbide, Syalon and Stellite are discussed, principally from the standpoint of minimising drawing force and die wear. Generally, the experimental and theoretical results were in good agreement, the drawing stress could be predicted within close limits and the process proved to be technically feasible. Finite element analysis has been carried out on the various die geometries and die materials, to gain a greater understanding of the behaviour of these dies under the process of elevated temperature drawing, and to establish the temperature distribution and thermal distortion in the deforming zone, thus establishing the optimum die design and die material for the process. It is now possible to predict, for the materials already tested, (i) the optimum drawing temperature range, (ii) the maximum possible reduction of area per pass, (iii) the optimum drawing die profiles and die materials, (iv) the most efficient lubricant in terms of reducing the drawing force and die wear.

The mechanics of ultrasonic tube bending

The technology of precision bending of tubes has recently increased in importance and is widely demanded for many industrial applications. However, whilst attention has been concentrated on automation and increasing the production rate of the bending machines, it seems that with one exception very little work has been done in order to understand and therefore fundamentally improve the bending process. A new development for the process of draw-bending of tubes, in which the supporting mandrel is axially vibrated at an ultrasonic frequency, has been perfected. A research programme was undertaken to study the mechanics of tube• bending under both vibratory and non-vibratory conditions. For this purpose, a conventional tube-bending machine was modified and equipped with an oscillatory system. Thin-walled mild steel tubes of different diameter to thickness ratios were bent to mean bend radii having various values from 1.5 to 2.0 times the tube diameter. It was found that the application of ultrasonic vibration reduces the process forces and that the force reduction increases with increasing the vibration amplitude. A reduction in the bending torque of up to 30 per cent was recorded and a reduction in the maximum tube-wall thinning of about 15 per cent was observed. The friction vector reversal mechanism as well as a reduction in friction account for the changes of the forces and the strains. Monitoring the mandrel friction during bending showed, in some cases, that the axial vibration reverses the mandrel .mean force from tension to compression and, thus, the mandrel is assisting the tube motion instead of resisting it. A theory has been proposed to describe the mechanics of deformation during draw-bending of tubes, which embodies the conditions of both "with" and "without" mandrel axial vibration. A theoretical analysis, based on the equilibrium of forces approach, has been developed in which the basic process parameters were taken into consideration. The stresses, the strains and the bending torque were calculated utilising this new solution, and a specially written computer programme was used to perform the computations. It was shown that the theory is in good agreement with the measured values of the strains under vibratory and non-vibratory conditions. Also, the predicted bending 'torque showed a similar trend to that recorded experimentally.

Metakaolin as a cement extender

The effect of 10% and 20% replacement metakaolin on a number of aspects of hydration chemistry and service performance of ordinary Portland cement pastes has been investigated. The analysis of expressed pore solutions has revealed that metakaolin-blended specimen pastes possess enhanced chloride binding capacities and reduced pore solution pH values when compared with their unblended counterparts. The implications of the observed changes in pore solution chemistry with respect to chloride induced reinforcement corrosion and the reduction in expansion associated with the alkali aggregate reaction are discussed. Differential thermal analysis, mercury intrusion porosimetry, and nuclear magnetic resonance spectroscopy have been employed in the analysis of the solid phase. It is suggested that hydrated gehlenite (a product of pozzolanic reaction) is operative in the removal and solid state binding of chloride ions from the pore solution of metakaolin-blended pastes. Diffusion coefficients obtained in a non-steady state chloride ion diffusion investigation have indicated that cement pastes containing 10% and 20% replacement metakaolin exhibit superior resistance to the penetration of chloride ions in comparison with those of plain OPC of the same water:cement ratio. The chloride induced corrosion behaviour of cement paste samples, of water:cement ratio 0.4, containing 0% , 10%, and 20% replacement metakaolin, has been monitored using the linear polarization technique. No significant corrosion of embedded mild steel was observed over a 200 day period.

Corrosion inhibitors for the rehabilitation of reinforced concrete

Four corrosion inhibitors namely sodium nitrite, sodium monofluorophosphate, ethanolamine and an alkanolamine-based mixture were studied by immersing mild steel bars for 42 days in model electrolytes of varied pH and chloride concentration which were intended to simulate the pore solution phase present within carbonated and/or chloride-contaminated concrete. Site trials were carried out on sodium monofluorophosphate and the alkanolamine-based inhibitor to study their depth of penetration into concrete. The influence of various carbonating atmospheres on the pore solution chemistry and microstructure of hydrated cement paste was investigated. Physical realkalisation of carbonated cement paste and a calcium nitrite-based corrosion rehabilitation system for chloride-contaminated cement paste were investigated by monitoring ionic transport within the pore solution phase of laboratory specimens. The main findings were as follows: 1,Sodium nitrite, sodium monofluorophosphate, ethanolamine and the alkanolamine-based mixture all behaved as passivating anodic inhibitors of steel corrosion in air-saturated aqueous solutions of varied pH and chloride concentration. 2,Sodium monofluorophosphate failed to penetrate significantly into partially carbonated site concrete when applied as recommended by the supplier. Phosphate and fluoride penetrated 5mm into partially carbonated site concrete treated with sodium monofluorophosphate. 3,The ethanolamine component of the alkanolamine-based inhibitor was found to have penetrated significant depths into partially carbonated site concrete. 4,Carbonating hydrated cement paste over saturated solutions of sodium nitrite resulted in significant concentrations of nitrite in the pore solution of the carbonated paste. Saturated solutions of sodium chloride, ammonium nitrate, magnesium nitrate and sodium dichromate were investigated and identified as alternatives for controlling the relative humidity of the carbonating environment. 5,Hardened carbonated cement paste can by physically realkalised to a limited extent due to the diffusion of hydroxyl ions under saturated conditions. A substantial proportion of the hydroxyl ions that diffused into the carbonated cement paste however, became bound into the cement matrix. Hydroxyl ion concentrations remained below 5mmol/l within the pore solution of the realkalised cement paste. 6, Nitrite ions penetrated significant distances by diffusion within the pore solution of saturated uncarbonated hydrated cement paste.

A failure criterion for fillet welds

The work constitutes a study of the strength of mild steel fillet welds subject to static loading, and the behaviour of flange welded beam-column connections under combined bending and shear. Tests are conducted on short welds in the as-welded and stress relieved conditions, and also on full-size beam-column connections. It is shown that welds under compression have a lower strength than when under tension. Failure of the fillet weld is initiated at the weld root, the important factor controlling the initiation being weld ductility. The greater the residual stress, the lower the weld ductility and ultimate strength. Thermal stress relieving increases strength by as much as 30%. Weld failure plane is rarely at the throat and varies from 0° to 45° depending upon loading condition. Failure plane average stresses are related by a circular function which is expressed in terms of externally applied forces at limit state. The tension weld of a flange-welded beam-column connection always fails before the compression weld. The shear load sharing between the welds is a complex function of elastic compression of the web, elastic/plastic deformation of the flanges, load/deformation characteristics, and the type of load application. Bearing forces between the compression flange and column face produce low level bearing stresses and frictional forces which make a negligible contribution to shear load resistance. Three modes of connection failure are possible; 'end mode', 'bending mode' and 'shear mode', with a sudden change taking place between the two latter.

Technology of repair for corroded reinforced concrete

A number of factors relating to various methods of repair for chloride initiated corrosion damage of reinforced concrete have been studied. A novel methodology has been developed to facilitate the measurement of macro and micro-cell corrosion rates for steel electrodes embedded in mortar prisms containing a chloride gradient. The galvanic bar specimen comprised electrically isolatable segmental mild steel electrodes and was constructed such that macro-cell corrosion currents were determinable for a number of electrode combinations. From this, the conditions giving rise to an incipient anode were established. The influence of several reinforcement and substrate primer systems upon macro-cell corrosion, arising from an incipient anode, within a patch repair have been investigated. Measurements of electrochemical noise were made in order to investigate the suitability of the technique as an on-site means of assessing corrosion activity within chloride contaminated reinforced concrete. For this purpose the standard deviation of potential noise was compared to macro-cell galvanic current data and micro-cell corrosion intensity determined by linear polarisation. Hydroxyl ion pore solution analyses were carried out on mortar taken from cathodically protected specimens. These specimens, containing sodium chloride, were cathodically protected over a range of polarisation potentials. Measurement of the hydroxyl ion concentrations were made in order to examine the possibility of alkali-silica reactions initiated by cathodic protection of reinfored concrete. A range of mortars containing a variety of generic type additives were examined in order to establish their resistances to chloride ion diffusion. The effect of surfactant addition rate was investigated within a cement paste containing various dosages of naphthalene sulphonate.

Die load and stresses in press forging

Several axi-symmetric EN3B steel components differing in shape and size were forged on a 100 ton joint knuckle press. A load cell fitted under the lower die inserts recorded the total deformation forces. Job parameters were measured off the billets and the forged parts. Slug temperatures were varied and two lubricants - aqueous colloidal graphite and oil - were used. An industrial study was also conducted to check the results of the laboratory experiments. Loads were measured (with calibrated extensometers attached to the press frames) when adequately heated mild steel slugs were being forged in finishing dies. Geometric parameters relating to the jobs and the dies were obtained from works drawings. All the variables considered in the laboratory study could not, however, be investigated without disrupting production. In spite of this obvious limitation, the study confirmed that parting area is the most significant geometric factor influencing the forging load. Multiple regression analyses of the laboratory and industrial results showed that die loads increase significantly with the weights and parting areas of press forged components, and with the width to thickness ratios of the flashes formed, but diminish with increasing slug temperatures and higher billet diameter to height ratios. The analyses also showed that more complicated parts require greater loads to forge them. Die stresses, due to applied axial loads, were investigated by the photoelastic method. The three dimensional frozen stress technique was employed. Model dies were machined from cast araldite cylinders, and the slug material was simulated with plasticene. Test samples were cut from the centres of the dies after the stress freezing. Examination of the samples, and subsequent calculations, showed that the highest stresses were developed in die outer corners. This observation partly explains why corner cracking occurs frequently in industrial forging dies. Investigation of die contact during the forging operation revealed the development of very high stresses.

The transition from severe to mild wear in law alloy steel

The wear rates of sliding surfaces are significantly reduced if mild oxidational wear can be encouraged. It is hence of prime importance in the interest of component life and material conservation to understand the factors necessary to promote mild, oxidational wear, The present work investigates the fundamental mechanism of the running-in wear of BS EN 31!EN 8 steel couples. under various conditions of load. speed and test duration. Unidirectional sliding experiments were carried out on a pin-on~disc wear machine where frictional force, wear rate, temperature and contact resistance were continuously monitored during each test. Physical methods of analysis (x-ray, scanning electron microscopy etc.) were used to examine the wear debris and worn samples. The wear rate versus load curves revealed mild wear transitions, which under long duration of running, categorized mild wear into four distinct regions.α-Fe20s. Fe304, FeO and an oxide mixture were the predominant oxides in four regions of oxidational wear which were identified above the Welsh T2 transition. The wear curves were strongly effected by the speed and test duration. A surface model was used to calculate the surface parameters, and the results were found to be comparable with the experimentally observed parameters. Oxidation was responsible for the transition from severe to mild wear at a load corresponding to the Welsh T2 transition. In the running-in period sufficient energy input and surface hardness enabled oxide growth rate to increase and eventually exceeded the rate of removal, where mild wear ensued. A model was developed to predict the wear volume up to the transition. Remarkable agreement was found between the theoretical prediction and the experimentally-measured values. The oxidational mechanjsm responsible for transitjon to mild wear under equilibrium conditions was related to the formation of thick homogenous oxide plateaux on subsurface hardened layers, FeO was the oxide formed initially at the onset of mild wear but oxide type changed.during the total running period to give an equilibrium oxide whose nature depended on the loads applied.