Study of fracture behaviour of bond coats on nickel superalloy by three-point bending of microbeams

A microbeam testing geometry is designed to study the variation in fracture toughness across a compositionally graded NiAl coating on a superalloy substrate. A bi-material analytical model of fracture is used to evaluate toughness by deconvoluting load-displacement data generated in a three-point bending test. It is shown that the surface layers of a diffusion bond coat can be much more brittle than the interior despite the fact that elastic modulus and hardness do not display significant variations. Such a gradient in toughness allows stable crack propagation in a test that would normally lead to unstable fracture in a homogeneous, brittle material. As the crack approaches the interface, plasticity due to the presence of Ni3Al leads to gross bending and crack bifurcation.

Thermal Weight Functions and Stress Intensity Factors for Bonded Dissimilar Media Using Body Analogy

In this study, an analytical method is presented for the computation of thermal weight functions in two dimensional bi-material elastic bodies containing a crack at the interface and subjected to thermal loads using body analogy method. The thermal weight functions are derived for two problems of infinite bonded dissimilar media, one with a semi-infinite crack and the other with a finite crack along the interface. The derived thermal weight functions are shown to reduce to the already known expressions of thermal weight functions available in the literature for the respective homogeneous elastic body. Using these thermal weight functions, the stress intensity factors are computed for the above interface crack problems when subjected to an instantaneous heat source.

Computation of stress intensity factors by the sub-region mixed finite element method of lines

Based on the sub-region generalized variational principle, a sub-region mixed version of the newly-developed semi-analytical 'finite element method of lines' (FEMOL) is proposed in this paper for accurate and efficient computation of stress intensity factors (SIFs) of two-dimensional notches/cracks. The circular regions surrounding notch/crack tips are taken as the complementary energy region in which a number of leading terms of singular solutions for stresses are used, with the sought SIFs being among the unknown coefficients. The rest of the arbitrary domain is taken as the potential energy region in which FEMOL is applied to obtain approximate displacements. A mixed system of ordinary differential equations (ODEs) and algebraic equations is derived via the sub-region generalized variational principle. A singularity removal technique that eliminates the stress parameters from the mixed equation system eventually yields a standard FEMOL ODE system, the solution of which is no longer singular and is simply and efficiently obtained using a standard general-purpose ODE solver. A number of numerical examples, including bi-material notches/cracks in anti-plane and plane elasticity, are given to show the generally excellent performance of the proposed method.

折线裂纹和两相材料界面的相互作用

利用螺位错基本解建立了和界面相交的折线裂纹的Cauchy型积分方程．根据奇异积分方程理论，得出了确定折线裂纹和界面交点处的奇性应力指数的特征方程，以及交点处各角形域内的奇性应力．利用所得的交点处的奇性应力定义了折线裂纹和界面交点处的应力强度因子．对所得积分方程进行数值求解，可得裂纹端点以及裂纹和界面交点处的应力强度因子．

Micromechanical Modelling of Non-Homogenous Materials by Meshless Methods

A detailed study of bi-material composites, using meshless methods (MMs), is presented in this paper. Firstly, representative volume elements (RVEs) for different bi-material combinations are analysed by the element-free Galerkin (EFG) method in order to confirm the effective properties of heterogeneous material through homogenization. The results are shown to be in good agreement with experimental results and those obtained using the finite element method (FEM) which required a higher node density. Secondly, a functionally graded material (FGM), with a crack, is analysed using the EFG method. This investigation was motivated by the possibility of replacing the distinct fibrematrix interface with a FGM interface. Finally, an illustrative example showing crack propagation, in a two-dimension micro-scale model of a SiC/Al composite is presented. 

A hybrid embedded cohesive element method for predicting matrix cracking in composites

The complex architecture of many fibre-reinforced composites makes the generation of finite element meshes a labour-intensive process. The embedded element method, which allows the matrix and fibre reinforcement to be meshed separately, offers a computationally efficient approach to reduce the time and cost of meshing. In this paper we present a new approach of introducing cohesive elements into the matrix domain to enable the prediction of matrix cracking using the embedded element method. To validate this approach, experiments were carried out using a modified Double Cantilever Beam with ply drops, with the results being compared with model predictions. Crack deflection was observed at the ply drop region, due to the differences in stiffness, strength and toughness at the bi-material interface. The new modelling technique yields accurate predictions of the failure process in composites, including fracture loads and crack deflection path.

Análisis del proceso de Friction Drilling: Análisis de la calidad de la junta atornillada

[ES]En el presente trabajo, se pretende optimizar la unión atornillada de chapas de dos materiales disimilares (acero y aluminio) mediante un proceso no convencional, el taladrado por fricción. Dicho proceso está orientado a la calderería fina, sector en el cual tiene gran número de aplicaciones. Se comenzará con una serie de ensayos iníciales y se procederá a realizar pruebas sistemáticas. Se realizarán mediciones de temperaturas, momentos torsores y fuerzas, y se analizaran las tolerancias dimensionales generadas por el proceso para la elección de los parámetros óptimos. El documento se centrará en analizar de forma teórica el comportamiento mecánico de la unión y de los ensayos de tracción correspondientes. Esto servirá para realizar los futuros ensayos de calidad y posteriormente comparar los resultados con los de las uniones convencionales.

Reutilización de escoria negra de acería como soporte en biofiltros para la eliminación de H2S del biogás.

[EN]Due to the limitations associated with fossil fuels it is necessary to promote energy sources that are renewable as well as eco-friendly, such as biogas generated in anaerobic digesters. The biogas, composed principally of methane and CO2, is the result of the biodegradation of organic matter under anaerobic conditions. Its use as fuel is limited by the presence of minority compounds such as hydrogen sulphide (H2S); therefore, its pre-treatment is necessary. Currently there are various technologies for the removal of H2S from a gas stream, but most of them are based on physic-chemical treatments which have a number of drawbacks as reactive consumption, generation of secondary flows, etc. Biofiltration has been used as an efficient and low cost alternative to conventional purification processes, and excellent results for the degradation of H2S have been obtained. However process can be limited due to the progressive ageing of the support material, along with the loss of nutrients and other specific characteristics necessary for the good development of biomass. The purpose of this project is to develop a mixed support consisting of a mixture of an organic material and an inorganic support for its application in the removal of the H2S from biogas. This support material helps to optimize the characteristics of the bed and extend its lifespan. The development of such material will contribute to the implementation of biofiltration for treating biogas from anaerobic digesters for its use as biofuel. The inorganic material used is electric arc furnace (EAF) black slag, a by-product generated in large quantities in the production of steel in the Basque Country. Although traditionally the slag has been used in civil engineering, its physicochemical characteristics make it suitable for reuse as a filter medium in biofiltration. The main conclusion drawn from the experimental results is that EAF black slag is a suitable co-packing material in organic biofilters treating H2S-polluted gaseous streams. High pollutant removal rates have been achieved during the whole experimental period. The removal capacity recorded in biofilters with less inorganic material was higher than in those with higher slag portion. Nevertheless, all the biofilters have shown a satisfactory response even at high inlet loads (48 g·m-3·h-1), where the RE has not decreased over 82%.

An investigation of electrolytic surface damages and electroplated crhomium effects on fatigue behavior of high strength steel

Fatigue crack initiation occurs at the surface, although sub surface nucleation has also been reported. Localized imperfections like inclusions close to surface and surface small pits can result in crack sources. Coatings are not always beneficial by fatigue point of view too. Mechanical properties of the covering material can change considerably the fatigue behavior of base metal due to residual surface stresses, to micro cracks or to hydrogen embrittlement. This paper is concerned with analysis of electrolytic etch on the fatigue resistance of a 35NCD16 high strength steel in a mechanical condition of (1760 - 1960) MPa, and analysis of electroplated hard chromium effects on the fatigue resistance in a strength condition of 989 MPa. Hardness impression was used as a reference parameter in case of electrolytic etch. In both cases, experimental data showed that fatigue strength of 35NCD16 steel was considerably reduced. Copyright © 2001 Society of Automotive Engineers, Inc.

A material model for flexural crack simulation in reinforced concrete elements using ABAQUS

This paper presents a material model to simulate load induced cracking in Reinforced Concrete (RC) elements in ABAQUS finite element package. Two numerical material models are used and combined to simulate complete stress-strain behaviour of concrete under compression and tension including damage properties. Both numerical techniques used in the present material model are capable of developing the stress-strain curves including strain softening regimes only using ultimate compressive strength of concrete, which is easily and practically obtainable for many of the existing RC structures or those to be built. Therefore, the method proposed in this paper is valuable in assessing existing RC structures in the absence of more detailed test results. The numerical models are slightly modified from the original versions to be comparable with the damaged plasticity model used in ABAQUS. The model is validated using different experiment results for RC beam elements presented in the literature. The results indicate a good agreement with load vs. displacement curve and observed crack patterns.

Spatial Wavelet Approach to Local Matrix Crack Detection in Composite Beams with Ply Level Material Uncertainty

Wavelet coefficients based on spatial wavelets are used as damage indicators to identify the damage location as well as the size of the damage in a laminated composite beam with localized matrix cracks. A finite element model of the composite beam is used in conjunction with a matrix crack based damage model to simulate the damaged composite beam structure. The modes of vibration of the beam are analyzed using the wavelet transform in order to identify the location and the extent of the damage by sensing the local perturbations at the damage locations. The location of the damage is identified by a sudden change in spatial distribution of wavelet coefficients. Monte Carlo Simulations (MCS) are used to investigate the effect of ply level uncertainty in composite material properties such as ply longitudinal stiffness, transverse stiffness, shear modulus and Poisson's ratio on damage detection parameter, wavelet coefficient. In this study, numerical simulations are done for single and multiple damage cases. It is observed that spatial wavelets can be used as a reliable damage detection tool for composite beams with localized matrix cracks which can result from low velocity impact damage.

Microstructure Development, Nanomechanical, and Dynamic Compression Properties of Spark Plasma Sintered TiB2-Ti-Based Homogeneous and Bi-layered Composites

The growing threats due to increased use of small-caliber armor piercing projectiles demand the development of new light-weight body armor materials. In this context, TiB2 appears to be a promising ceramic material. However, poor sinterability and low fracture toughness remain two major issues for TiB2. In order to address these issues together, Ti as a sinter-aid is used to develop TiB2-(x wt pct Ti), (x = 10, 20) homogeneous composites and a bi-layered composite (BLC) with each layer having Ti content of 10 and 20 wt pct. The present study uniquely demonstrates the efficacy of two-stage spark plasma sintering route to develop dense TiB2-Ti composites with an excellent combination of nanoscale hardness (similar to 36 GPa) and indentation fracture toughness (similar to 12 MPa m(1/2)). In case of BLC, these properties are not compromised w.r.t. homogeneous composites, suggesting the retention of baseline material properties even in the bi-layer design due to optimal relief of residual stresses. The better indentation toughness of TiB2-(10 wt pct Ti) and TiB2-(20 wt pct Ti) composites can be attributed to the observed crack deflection/arrest, indicating better damage tolerance. Transmission electron microscope investigation reveals the presence of dense dislocation networks and deformation twins in alpha-Ti at the grain boundaries and triple pockets, surrounded by TiB2 grains. The dynamic strength of around 4 GPa has been measured using Split Hopkinson Pressure Bar tests in a reproducible manner at strain rates of the order of 600 s(-1). The damage progression under high strain rate has been investigated by acquiring real time images for the entire test duration using ultra-high speed imaging. An attempt has been made to establish microstructure-property correlation and a simple analysis based on Mohr-Coulomb theory is used to rationalize the measured strength properties.

Matrix Crack Detection in Composite Plate with Spatially Random Material Properties using Fractal Dimension

Fractal dimension based damage detection method is investigated for a composite plate with random material properties. Composite material shows spatially varying random material properties because of complex manufacturing processes. Matrix cracks are considered as damage in the composite plate. Such cracks are often seen as the initial damage mechanism in composites under fatigue loading and also occur due to low velocity impact. Static deflection of the cantilevered composite plate with uniform loading is calculated using the finite element method. Damage detection is carried out based on sliding window fractal dimension operator using the static deflection. Two dimensional homogeneous Gaussian random field is generated using Karhunen-Loeve (KL) expansion to represent the spatial variation of composite material property. The robustness of fractal dimension based damage detection method is demonstrated considering the composite material properties as a two dimensional random field.

Crack propagation in the power-law nonlinear viscoelastic material

An analysis on crack creep propagation problem of power-law nonlinear viscoelastic materials is presented. The creep incompressilility assumption is used. To simulate fracture behavior of craze region, it is assumed that in the fracture process zone near the crack tip, the cohesive stress sigma(f) acts upon the crack surfaces and resists crack opening. Through a perturbation method, i. e., by superposing the Mode-I applied force onto a referential uniform stress state, which has a trivial solution and gives no effect on the solution of the original problem, the nonlinear viscoelastic problem is reduced to linear problem. For weak nonlinear materials, for which the power-law index n similar or equal to 1, the expressions of stress and crack surface displacement are derived. Then, the fracture process zone local energy criterion is proposed and based on which the formulas of cracking incubation time t

Torsional impact response of a penny-shaped interface crack in bonded materials with a graded material interlayer

In this paper, the dynamic response of a penny-shaped interface crack in bonded dissimilar homogeneous half-spaces is studied. It is assumed that the two materials are bonded together with such a inhomogeneous interlayer that makes the elastic modulus in the direction perpendicular to the crack surface is continuous throughout the space. The crack surfaces art assumed to be subjected to torsional impact loading. Laplace and Hankel integral transforms are applied combining with a dislocation density,function to reduce the mixed boundary value problem into a singular integral equation with a generalized Cauchy kernel in Laplace domain. By solving the singular integral equation numerically, and using a numerical Laplace inversion technique, the dynamic stress intensity factors art obtained. The influences of material properties and interlayer thickness on the dynamic stress intensity factor are investigated.