Failure modes and fatigue behavior of conventional and refilled friction stir spot welds in AA 6061-T6 sheets

The fatigue behavior of conventional friction stir spot welding (FSSW) and friction stir spot welding refilled by the friction forming process (FSSW-FFP) in aluminum 6061-T6 lap shear specimens, are investigated based on the experimental observations. Optical micrographs of the welds after fatigue failure in both the cases are examined to study the fatigue crack propagation and failure modes. Experimental results indicate that the fatigue strength of the FSSW-FFP weld samples is higher than that of the conventional FSSW samples at all loads. Fracture surfaces are analyzed in detail using the scanning electron microscope. (C) 2013 Elsevier Ltd. All rights reserved.

Static shear strength and fatigue life of refill friction stir spot welded AA 6061-T6 sheets

This study was aimed at evaluating the static shear strength and fatigue properties of the newly developed refilled friction stir spot welded AA 6061-T6 joints. The keyhole, the process disadvantage of conventional friction stir spot welding, was refilled successfully, using an additional filler plate, with specially designed tools. Two different tool profiles, namely, convex and concave, were used for the refilling process. Sound and defect free joints were obtained by the refilling process. Joints refilled with convex tools showed better static shear strength than those with the concave ones. The variation of microhardness in different regions of the weld was analysed. Fatigue tests were conducted on the lap shear specimens at a stress ratio of R=0.1. The optical micrographs of the welds after fatigue failure in both the conventional and refilled processes were examined to study the fatigue crack propagation and failure modes.

Evolution of texture and its influence on the failure of components in some aluminium alloys

This paper describes the evolution of crystallographic texture in three of the most important high strength aluminium alloys, viz., AA2219, AA7075 and AFNOR7020 in the cold rolled and artificially aged condition. Bulk texture results were obtained by plotting pole figures from X-ray diffraction results followed by Orientation Distribution Function (ODF) analysis and micro-textures were measured using EBSD. The results indicate that the deformation texture components Cu, Bs and S, which were also present in the starting materials, strengthen with increase in amount of deformation. On the other hand, recrystallization texture components Goss and Cube weaken. The Bs component is stronger in the deformation texture. This is attributed to the shear banding. In-service applications indicate that the as-processed AFNOR7020 alloy fails more frequently compared to the other high strength Al alloys used in the aerospace industry. Detailed study of deformation texture revealed that strong Brass (Bs) component could be associated to shear banding, which in turn could explain the frequent failures in AFNOR7020 alloy. The alloying elements in this alloy that could possibly influence the stacking fault energy of the material could be accounted for the strong Bs component in the texture.

Mechanism on Progressive Failure of a Faulted Rock Slope Due to Slip-Weakening

Slip-weakening is one of the characteristics of geological materials under certain loadings. Non-uniform rock structure may exist in the vicinity of the slip surface for a rock slope. Some portion of the slip surface may be penetrated but the other not. For the latter case, the crack or the fault surface will undergo shear deformation before it becomes a successive surface under a certain loading. As the slipped portion advances,slip-weakening occurs over a distance behind the crack tip. In the weakening zone, the shear strength will decrease from its peak value to residual friction level. The stress will redistribute along the surface of crack and in the weakening zone. Thus the changed local stress concentration leads the crack to extend and the ratio of penetration of the slip surface to increase. From the view of large-scale for the whole slip surface, the shear strength will decrease due to the damage of interior rock structure, and the faulted rock behaves as a softening material. Such a kind of mechanism performs in a large number of practical landslides in the zones experienced strong earthquakes. It should be noted that the mechanism mentioned above is different from that of the breakage of structural clay,in which the geological material is regarded as a medium containing structural lumps and structural bands. In this paper, the softening behavior of a faulted rock should be regarded as a comprehensive result of the whole complicated process including slip-weakening, redistribution of stress, extension of crack tip, and the penetration of the slip surface. This process is accompanied by progressive failure and abrupt structural damage. The size of slip-weakening zone is related to the undergoing strain. Once the relative slide is initiated (local or integrated), the effect of slip-weakening will behave in a certain length behind the crack tip until the formation of the whole slip surface.

Shear deformation analysis on laser-induced reverse bulging and plugging

A new kind of failure mode is observed in circular brass foils in which their peripheries are fixed and their surfaces are subjected to a long pulsed laser over a central region. The failure is classified into three stages; they are referred to as thermal bulging, localized shear deformation and perforation by plugging. A distinct feature of the failure mode is that bulging and plugging occurred in the direction opposite to the incident laser beam. To study the failure mode, we investigate the non-linear response of heated, non-homogeneous circular plates. Based on the large deflection equations of Berger [J. Appl. Mech. 22 (3), 465-472 (1965)], Ohnabe and Mizuguchi [Int. J. Non-Linear Mech. 28 (4), 365-372 (1993)] and the parabolic shear deformation theory of Bhimaraddi and Stevens [J. Appl. Mech. 51 (1), 195-198 (1984)], we have derived new coupled governing equations of shear deformation and deflection. The new equations are solved, for the plate with a clamped edge, by the Galerkin and iterative methods. The numerical results for the shear deformation distribution are in good agreement with the experimental observation.

The investigation on dynamic fracture behavour of materials under compressive-shear combined stress waves

In this paper, an improved plate impact experimental technique is presented for studying dynamic fracture mechanism of materials, under the conditions that the impacting loading is provided by a single pulse and the loading time is in the sub-microsecond range. The impacting tests are carried out on the pressure-shear gas gun. The loading rate achieved is dK/dt similar to 10(8) MPa m(1/2) s(-1). With the elimination of influence of the specimen boundary, the plane strain state of a semi-infinite crack in an infinite elastic plate is used to simulate the deformation fields of crack tip. The single pulses are obtained by using the "momentum trap" technique. Therefore, the one-time actions of the single pulse are achieved by eradicating the stress waves reflected from the specimen boundary or diffracted from the crack surfaces. In the current study, some important phenomena have been observed. The special loading of the single pulse can bring about material damage around crack tip, and affect the material behavior, such as kinking and branching of the crack propagation. Failure mode transitions from mode I to mode II crack are observed under asymmetrical impact conditions. The mechanisms of the dynamic crack propagation are consistent with the damage failure model.

Comparison Of Shear Banding In Bmgs Due To Thermal-Softening And Free Volume Creation

This paper reports a comparative study of shear banding in BMGs resulting from thermal softening and free volume creation. Firstly, the effects of thermal softening and free volume creation on shear instability are discussed. It is known that thermal softening governs thermal shear banding, hence it is essentially energy related. However, compound free volume creation is the key factor to the other instability, though void-induced softening seems to be the counterpart of thermal softening. So, the driving force for shear instability owing to free volume creation is very different from the thermally assisted one. In particular, long wave perturbations are always unstable owing to compound free volume creation. Therefore, the shear instability resulting from coupled compound free volume creation and thermal softening may start more like that due to free volume creation. Also, the compound free volume creation implies a specific and intrinsic characteristic growth time of shear instability. Finally, the mature shear band width is governed by the corresponding diffusions (thermal or void diffusion) within the band. As a rough guide, the dimensionless numbers: Thermal softening related number B, Deborah number (denoting the relation of instability growth rate owing to compound free volume and loading time) and Lewis number (denoting the competition of different diffusions) show us their relative importance of thermal softening and free volume creation in shear banding. All these results are of particular significance in understanding the mechanism of shear banding in bulk metallic glasses (BMGs).

Micromechanics analysis of particulate-reinforced composites and their failure mechanisms

Stress fields and failure mechanisms have been investigated in composites with particles either surface treated or untreated under uniaxial tension. Previous experimental observation of failure mechanisms in a composite with untreated particles showed that tensile cracks occurred mostly at the polar region of the particle and grew into interfacial debonding. In a composite with surface-treated particles, however, shear yielding and shear cracking proceeded along the interphase-matrix interface at the polar area of the matrix and thus may improve the mechanical behaviour of the material. The finite element calculations showed that octahedral shear stress at the polar and longitudinal areas of the particle treated by coupling agents is much larger than that of materials with untreated particles, and the shear stress distribution around the interface is sensitive to the interphase property. The results suggest that a th ree-phase model can describe the composites with surface-treated fillers.

Formation of shear bands in plane sheet

The formation of shear bands in plane sheet is studied, both analytically and experimentally, to enhance the fundamental understanding of this phenomenon and to develop a capability for predicting material failure. The evolution of voids is measured and its interaction with the process of shear banding is examined. The evolving dilatancy in plasticity is shown to have a vital role in analysing the shear-band type of bifurcation, and tremendously reduces the theoretical value of critical stresses. The analyses, referring to both localized and diffuse modes of bifurcation, fairly explain the corresponding observations obtained through testing a dual-phase steer sheet and provide a justification of the constitutive model used.

On post-instability processes in adiabatic shear in hot rolled steel

EXPERIMENTS carried out using a split Hopkinson torsional bar have shown that only one shear band develops in specimens of hot rolled steel which break during testing. We observed, however, that in specimens which were not deformed to failure, several fine shear bands appeared. We believe that these formed during the loading cycle before the appearance of the final shear band and were not due to the effect of unloading. So we developed a numerical model to study the evolution of shear banding from several finite amplitude disturbances (FADs) in both temperature and strain rate. This numerical model reveals the detailed processes by which the FADs evolve into a fully developed shear band and suggests that beyond instability, the so-called shear banding process consists of two stages: inhomogeneous shearing and true shear-banding. The latter is characterized by the collapse of the stress and an abrupt increase of the local shear strain rate.

Slope Stability Analysis Using Anisotropic and Nonlinear Failure Criteria

The shear strength of soils or rocks developed in a landslide usually exhibits anisotropic and nonlinear behavior. The process of sedimentation and subsequent consolidation can cause anisotropy of sedimentary soils or rocks, for instance. Nonlinearity of failure envelope could be attributed to "interlocking" or "dilatancy" of the material, which is generally dependent upon the stress level. An analytical method considering both anisotropy and nonlinearity of the failure envelops of soil and rocks is presented in the paper. The nonlinearfailure envelopes can be determined from routine triaxial tests. A spreadsheet program, which uses the Janbu's Generalized Procedure of Slice and incorporates anisotropic, illustrates the implementation of the approach and nonlinearfailure envelops. In the analysis, an equivalent Mohr-Coulomb linear failure criterion is obtained by drawing a tangent to the nonlinear envelope of an anisotropic soil at an appropriate stress level. An illustrative example is presented to show the feasibility and numerical efficiency of the method.

Adiabatic shear localization: occurrence, theories, and applications

Techniques to improve the shear strength of impacted bone graft: the effect of particle size and washing of the graft.

BACKGROUND: When fresh morselized graft is compacted, as in impaction bone-grafting for revision hip surgery, fat and marrow fluid is either exuded or trapped in the voids between particles. We hypothesized that the presence of incompressible fluid damps and resists compressive forces during impaction and prevents the graft particles from moving into a closer formation, thus reducing the graft strength. In addition, viscous fluid such as fat may act as an interparticle lubricant, thus reducing the interlocking of the particles. METHODS: We performed mechanical shear testing in the laboratory with use of fresh-frozen human femoral-head allografts that had been passed through different orthopaedic bone mills to produce graft of differing particle-size distributions (grading). RESULTS: After compaction of fresh graft, fat and marrow fluid continued to escape on application of normal loads. Washed graft, however, had little lubricating fluid and better contact between the particles, increasing the shear resistance. On mechanical testing, washed graft was significantly (p < 0.001) more resistant to shearing forces than fresh graft was. This feature was consistent for different bone mills that produced graft of different particle-size distributions and shear strengths. CONCLUSIONS: Removal of fat and marrow fluid from milled human allograft by washing the graft allows the production of stronger compacted graft that is more resistant to shear, which is the usual mode of failure. Further research into the optimum grading of particle sizes from bone mills is required.

Techniques to improve the shear strength of impacted bone graft: The effect of particle size and washing of the graft

Background: When fresh morselized graft is compacted, as in impaction bone-grafting for revision hip surgery, fat and marrow fluid is either exuded or trapped in the voids between particles. We hypothesized that the presence of incompressible fluid damps and resists compressive forces during impaction and prevents the graft particles from moving into a closer formation, thus reducing the graft strength. In addition, viscous fluid such as fat may act as an interparticle lubricant, thus reducing the interlocking of the particles. Methods: We performed mechanical shear testing in the laboratory with use of fresh-frozen human femoral-head allografts that had been passed through different orthopaedic bone mills to produce graft of differing particle-size distributions (grading). Results: After compaction of fresh graft, fat and marrow fluid continued to escape on application of normal loads. Washed graft, however, had little lubricating fluid and better contact between the particles, increasing the shear resistance. On mechanical testing, washed graft was significantly (p < 0.001) more resistant to shearing forces than fresh graft was. This feature was consistent for different bone mills that produced graft of different particle-size distributions and shear strengths. Conclusions: Removal of fat and marrow fluid from milled human allograft by washing the graft allows the production of stronger compacted graft that is more resistant to shear, which is the usual mode of failure. Further research into the optimum grading of particle sizes from bone mills is required. Clinical Relevance: Understanding the mechanical properties of milled human allograft is important when impaction grafting is used for mechanical support. A simple means of improving the mechanical strength of graft produced by currently available bone mills, including an intraoperative washing technique, is described.

Effects of solution exposure on the combined axial-shear behaviour of unidirectional CFRP rods

In fibre reinforced polymer (FRP) prestressed concrete applications, an FRP tendon must sustain high axial tensile stresses and, if cracks occur, additional dowel forces. The tendon may also be exposed to solutions and so the combined axial-shear stress performance after long-term environmental exposure is important. Experiments were conducted to investigate the combined axial-shear stress failure envelope for unidirectional carbon FRP tendons which had been exposed to either water, salt water or concrete pore solution at 60 °C for approximately 18 months. The underlying load resisting mechanisms were found to depend on the loading configuration, restraint effects and the initial stress state. When saturated, CFRP tendons are likely to exhibit a reduced shear stiffness. However, the ultimate limit state appeared to be fibre-dominated and was therefore less susceptible to reductions due to solution uptake effects. © 2012 Elsevier Ltd. All rights reserved.