Effect of Mechanical and Geometric Mismatching on Fatigue and Damage of Welded Joints

The future of high technology welded constructions will be characterised by higher strength materials and improved weld quality with respect to fatigue resistance. The expected implementation of high quality high strength steel welds will require that more attention be given to the issues of crack initiation and mechanical mismatching. Experiments and finite element analyses were performed within the framework of continuum damage mechanics to investigate the effect of mismatching of welded joints on void nucleation and coalescence during monotonic loading. It was found that the damage of undermatched joints mainly occurred in the sandwich layer and the damageresistance of the joints decreases with the decrease of the sandwich layer width. The damage of over-matched joints mainly occurred in the base metal adjacent to the sandwich layer and the damage resistance of the joints increases with thedecrease of the sandwich layer width. The mechanisms of the initiation of the micro voids/cracks were found to be cracking of the inclusions or the embrittled second phase, and the debonding of the inclusions from the matrix. Experimental fatigue crack growth rate testing showed that the fatigue life of under-matched central crack panel specimens is longer than that of over-matched and even-matched specimens. Further investigation by the elastic-plastic finite element analysis indicated that fatigue crack closure, which originated from the inhomogeneousyielding adjacent to the crack tip, played an important role in the fatigue crack propagation. The applicability of the J integral concept to the mismatched specimens with crack extension under cyclic loading was assessed. The concept of fatigue class used by the International Institute of Welding was introduced in the parametric numerical analysis of several welded joints. The effect of weld geometry and load condition on fatigue strength of ferrite-pearlite steel joints was systematically evaluated based on linear elastic fracture mechanics. Joint types included lap joints, angle joints and butt joints. Various combinations of the tensile and bending loads were considered during the evaluation with the emphasis focused on the existence of both root and toe cracks. For a lap joint with asmall lack-of-penetration, a reasonably large weld leg and smaller flank angle were recommended for engineering practice in order to achieve higher fatigue strength. It was found that the fatigue strength of the angle joint depended strongly on the location and orientation of the preexisting crack-like welding defects, even if the joint was welded with full penetration. It is commonly believed that the double sided butt welds can have significantly higher fatigue strength than that of a single sided welds, but fatigue crack initiation and propagation can originate from the weld root if the welding procedure results in a partial penetration. It is clearly shown that the fatigue strength of the butt joint could be improved remarkably by ensuring full penetration. Nevertheless, increasing the fatigue strength of a butt joint by increasing the size of the weld is an uneconomical alternative.

The role of Notch receptor signaling in T helper 17 cell differentiation

Antigenic recognition by naive CD4+ T cells induces their proliferation and differentiation into functionally distinct T helper (Th) cell. Each CD4+ Th cell subset expresses specific transcription factors and produces signature cytokines that coordinate immune responses against encountered pathogens. Among the factors influencing CD4+ Th cell differentiation, Notch signaling pathway has been reported to play a role in the differentiation and function of multiple CD4+Thcell subsets. Notch signaling is an evolutionarily conserved cell-to-cell signaling cascade involved in many cell fate decision processes. How Notch signaling modulates the differentiation of CD4+ Th cell subsets and whether Notch signaling alone is sufficient or not for the differentiation of CD4+ Th cells is still a matter of debate. Th17 cells are a distinct subset of CD4+ Th cells. They play a role in the control of extracellular bacterial and fungal infections and may lead to inflammatory and autoimmune diseases if not properly regulated. Th17 cells are defined by the expression of RAR-related orphan receptor (ROR)a and RORyT transcription factors and their secretion of IL-17A, IL-17F cytokines. The involvement of Notch signaling in Th17 cell differentiation has mostly been studied in vitro. However, neither the experimental conditions when Notch signaling might be involved in Th17 cell differentiation in vitro and in vivo nor the precise role of Notch in this process remain clear. To better define how Notch signaling impacts Th17 differentiation, we used mice with T cell specific ablation of Notchl and Notch2 (N1 N2ACD4Cre) or of Notch transcriptional repressor RBP- JK (RBP-J ACD4Cre). We show that impaired Notch signaling in T cells, when TCR activating signal were reduced, increased RORyT and IL-17 mRNA levels during in vitro Th17 cell differentiation. Following immunization with OVA in CFA, an adjuvant that induces mostly Th17 cell response, increased IL-17A mRNA and intracellular IL-17A levels were observed in draining lymph nodes of Notch-deficient CD4+T cells. Our data suggest that Notch limited Th17 cell differentiation. Despite high levels of IL-17 mRNA and intracellular IL-17 proteins observed in Notch-deficient T cells, their release of Th17 cytokines ex vivo was markedly decreased, indicating a role for Notch signaling. During the second part of this thesis, we observed that the impact of Notch on Th17 cell differentiation and effector functions was context-dependent using different in vivo experimental models, in which Th17 cells and IL-17A were reported to contribute in the disease development. Collectively, our data reveal that Notch signaling controls the fine-tuning of Th17 cell differentiation and effector functions by limiting their differentiation but promoting selectively cytokine release through Notch-dependent mechanisms that still need to be defined. -- Lors d'une réponse immunitaire et grâce à la reconnaissance antigénique, les lymphocytes CD4+ T naïfs prolifèrent, puis se différencient en CD4+ T auxiliaires ("T helper" ou Th) fonctionnellement distincts. Chaque sous-population de lymphocytes CD4+ T auxiliaires exprime des facteurs de transcription et des cytokines spécifiques qui coordonnent la réponse immunitaire contre les pathogènes rencontrés. Parmi les facteurs influençant la différenciation des lymphocytes CD4+ T auxiliaires, la voie de signalisation Notch a été identifiée comme ayant un rôle dans la différenciation et la fonction des différents sous-types de cellules CD4+ T auxiliaires. La voie de signalisation Notch est une voie évolutivement conservée, qui est impliquée dans la signalisation entre les cellules et dans de nombreux processus de décisions cellulaires. La manière dont la voie de signalisation Notch régule la différenciation des lymphocytes CD4+ T en sous-types de cellules CD4+ auxiliaires, mais également la question de savoir si la voie de signalisation Notch est capable ou non d'induire la différenciation des cellules CD4+T auxiliaires, restent à débattre. Les cellules T auxiliaires 17 (Th17) sont un sous-type distinct de cellules CD4+T. Elles jouent un rôle important dans la défense immunitaire contre des pathogènes tels que les bactéries extracellulaires et les champignons. Une dérégulation de la réponse des cellules Th17 peut conduire à des inflammations mais également à des maladies auto-immunes. Les cellules Th17 sont définies par l'expression de leurs facteurs de transcription RAR-related orphan receptor (ROR)a, RORyT et par la sécrétion de cytokines comme IL-17A, IL-17F. Le rôle de la voie de signalisation Notch dans la différenciation des cellules Th17 a principalement été démontré in vitro. Malgré tout, ni les conditions expérimentales dans lesquelles cette voie pourrait être impliquée dans la différenciation des cellules Th17 in vitro et in vivo, mais également ni la fonction exacte de Notch dans ces processus, ne sont des questions résolues. Afin de mieux définir comment la voie de signalisation Notch est impliquée dans la différenciation des cellules Th17, nous avons utilisé des souris avec une déficience spécifique dans les cellules T des récepteurs Notchl et Notch2 (N1N2ACD4Cre) ou du répresseur transcriptionnel de Notch RBP-JK (RBP-J ACD4Cre). Nous avons montré que lorsque la voie de signalisation Notch est déficiente, les niveaux d'ARN messager (ARNm) de RORyT et de IL-17A sont augmentés dans les cellules Th17 pendant la différenciation in vitro, en présence de niveaux réduits des signaux activant les cellules T CD4+. Une augmentation dans les niveaux d'ARNm de IL-17A et de IL-17A intracellulaire au niveau protéinique a été observée dans les cellules T CD4+ Notch déficientes, au niveau des ganglions drainants après immunisation avec l'OVA dans le CFA, un adjuvant induisant une réponse des cellules Th17. Nos résultats suggèrent que Notch pourrait réguler négativement l'expression de IL-17A au niveau transcriptionnel mais également protéinique. Malgré une augmentation de IL-17A au niveau de l'ARNm et protéinique dans les cellules CD4+ T Notch déficientes, paradoxalement la sécrétion de IL-17A mais également de cytokines associées aux fonctions effectrices des cellules Th17 sont profondément diminuées 6X vivo, suggérant un rôle de la voie de signalisation Notch dans ce processus. Dans la deuxième partie de ce travail de thèse, nous avons observé que l'impact de Notch dans la différenciation des cellules Th17 et dans leurs fonctions effectrices était dépendant du contexte dans d'autres modèles expérimentaux in vivo, où les cellules Th17 et l'IL-17A ont été identifiées comme ar-.riCociêSM dans le développement ds la pathologie. En résumé, nous avons montré que la voie de la signalisation Notch contrôle la régulation précise de la différenciation des cellules Th17 en limitant leur différenciation, mais en promouvant sélectivement leur relâchement en cytokines associés aux cellules Th17 par l'intermédiaire de mécanismes dépendant de Notch, qui restent toujours à déterminer. -- Lors d'une réponse immunitaire et grâce à la reconnaissance antigénique, les lymphocytes CD4+ T naïfs prolifèrent, puis se différencient en CD4+ T auxiliaires ("T helper" ou Th) fonctionnellement distincts. Chaque sous-population de lymphocytes T auxiliaires exprime des facteurs de transcription et des cytokines spécifiques qui coordonnent une réponse immunitaire contre différents pathogènes. Les mécanismes liés à la différenciation des lymphocytes CD4+ T auxiliaires sont complexes et régulés. Une mauvaise régulation de la différenciation des lymphocytes CD4+ T auxiliaires peut conduire à des maladies auto-immunes, mais également à des processus inflammatoires. Parmi les facteurs influençant la différenciation des lymphocytes T auxiliaires, la voie de signalisation Notch a été identifiée comme ayant un rôle dans la différenciation et la fonction des différents sous-types de cellules CD4+ T auxiliaires. La voie de signalisation Notch est une voie évolutivement conservée, qui est impliquée dans la signalisation entre les cellules, mais également dans de nombreux processus de décisions cellulaires. Quelle est l'implication de la voie de signalisation Notch dans la différenciation des lymphocytes CD4+ en sous-types de cellules CD4+T auxiliaires et comment cette voie agit dans ce processus, sont des questions débattues. Les cellules T auxiliaires 17 (Th17) sont une sous-population distincte de lymphocytes CD4+. Elles jouent un rôle important dans la défense immunitaire contre les bactéries extracellulaires et les champignons. Une dérégulation de la réponse des cellules Th17 a été associée à des maladies auto-immunes et à l'inflammation. Les cellules Th17 sont définies par l'expression du facteur de transcription RAR-related orphan receptor (ROR)yT et des cytokines comme IL-17A, IL-17F. Le rôle de la voie de signalisation Notch dans la différenciation des cellules Th17 a été principalement démontré dans des études expérimentales in vitro. Malgré tout, les conditions expérimentales exactes dans lesquelles la voie de signalisation de Notch pourrait être impliquée dans la différenciation des cellules Th17, mais également le rôle de Notch dans ce processus ne sont pas encore clairement élucidés. Afin de mieux définir comment la voie de signalisation Notch est impliquée dans la différenciation des cellules Th17, nous avons utilisé des souris avec une déficience spécifique dans les cellules T des récepteurs Notchl et Notch2 (N1 N2ACD4Cre) ou du répresseur transcriptionnel de Notch RBP-JK (RBP-JACD4CRE). Nous avons montré que lorsque la voie de signalisation Notch est déficiente, les niveaux d'ARN messager (ARNm) de RORyT et de IL-17 sont augmentés dans les cellules Th17 pendant leur différenciation in vitro. Cet effet de Notch sur la transcription apparaît être facultatif lorsque les conditions environnementales sont en excès in vitro. Après immunisation avec un adjuvant qui induit principalement une réponse des cellules Th17, nous avons observé que les niveaux de ARNm de IL-17A et aussi de IL-17A intracellulaire au niveau protéinique étaient augmentés dans les ganglions drainants dans les cellules CD4+ Notch déficientes. Ces résultats suggèrent que Notch pourrait réguler négativement l'expression de IL- 17 au niveau transcriptionnel mais également protéinique. Malgré des niveaux plus élevés de IL- 17 ARNm et aussi IL-17A intracellulaire dans les cellules T Notch déficientes, le relâchement en cytokines Th17 est profondément diminué indiquant un rôle de la voie de signalisation Notch dans ces processus de sécrétion. Dans la deuxième partie de cette thèse, nous avons observé que le rôle de Notch dans ia différenciation dss cellules Ti,17 et dans leurs fonctions effectrices était dépendant du contexte dans d'autres modèles expérimentaux, qui ont été rapportés comme une réponse induisant des cellules Th17. En résumé, nos données montrent que la voie de la signalisation Notch contrôle la régulation précise de la différenciation des cellules Th17 en limitant leur différenciation mais en promouvant sélectivement le relâchement en cytokines associées aux cellules Th17 par des mécanismes dépendant de Notch qui restent toujours à déterminer. Par conséquent, l'inhibition de la voie de signalisation Notch pourrait être utilisée dans des situations inflammatoires ou d'auto-immunité où la réponse des cellules Th17 est exacerbée.

Fusion weld metal solidification:Continuum from weld interface to centerline

We present a brief résumé of the history of solidification research and key factors affecting the solidification of fusion welds. There is a general agreement of the basic solidification theory, albeit differing - even confusing - nomenclatures do exist, and Cases 2 and 3 (the Chalmers' basic boundary conditions for solidification, categorized by Savage as Cases) are variably emphasized. Model Frame, a tool helping to model the continuum of fusion weld solidification from start to end, is proposed. It incorporates the general solidification models, of which the pertinent ones are selected for the actual modeling. The basic models are the main solidification Cases 1…4. These discrete Cases are joined with Sub-Cases: models of Pfann, Flemings and others, bringing needed Sub-Case variables into the model. Model Frame depicts a grain growing from the weld interface to its centerline. Besides modeling, the Model Frame supports education and academic debate. The new mathematical modeling techniques will extend its use into multi-dimensional modeling, introducing new variables and increasing the modeling accuracy. We propose a model: melting/solidification-model (M/S-model) - predicting the solute profile at the start of the solidification of a fusion weld. This Case 3-based Sub-Case takes into account the melting stage, the solute back-diffusion in the solid, and the growth rate acceleration typical to fusion welds. We propose - based on works of Rutter & Chalmers, David & Vitek and our experimental results on copper - that NEGS-EGS-transition is not associated only with cellular-dendritic-transition. Solidification is studied experimentally on pure and doped copper with welding speed range from 0 to 200 cm/min, with one test at 3000 cm/min. Found were only planar and cellular structures, no dendrites - columnar or equiaxed. Cell sub structures: rows of cubic elements we call "cubelettes", "cell-bands" and "micro-cells", as well as an anomalous crack morphology "crack-eye", were detected, as well as microscopic hot crack nucleus we call "grain-lag cracks", caused by a grain slightly lagging behind its neighbors in arrival to the weld centerline. Varestraint test and R-test revealed a change of crack morphologies from centerline cracks to grainand cell boundary cracks with an increasing welding speed. High speed made the cracks invisible to bare eye and hardly detectable with light microscope, while electron microscope often revealed networks of fine micro-cracks.

Targeted γ-Secretase Inhibition To Control the Notch Pathway in Renal Diseases.

Notch is a membrane inserted protein activated by the membrane-inserted γ-secretase proteolytic complex. The Notch pathway is a potential therapeutic target for the treatment of renal diseases but also controls the function of other cells, requiring cell-targeting of Notch antagonists. Toward selective targeting, we have developed the γ-secretase inhibitor-based prodrugs 13a and 15a as substrates for γ-glutamyltranspeptidase (γ-GT) and/or γ-glutamylcyclotransferase (γ-GCT) as well as aminopeptidase A (APA), which are overexpressed in renal diseases, and have evaluated them in experimental in vitro and in vivo models. In nondiseased mice, the cleavage product from Ac-γ-Glu-γ-secretase inhibitor prodrug 13a (γ-GT-targeting and γ-GCT-targeting) but not from Ac-α-Glu-γ-secretase inhibitor prodrug 15a (APA-targeting) accumulated in kidneys when compared to blood and liver. Potential nephroprotective effects of the γ-secretase inhibitor targeted prodrugs were investigated in vivo in a mouse model of acute kidney injury, demonstrating that the expression of Notch1 and cleaved Notch1 could be selectively down-regulated upon treatment with the Ac-γ-Glu-γ-secretase-inhibitor 13a.

Competition in notch signaling with cis enriches cell fate decisions

Notch signaling is involved in cell fate choices during the embryonic development of Metazoa. Commonly, Notch signaling arises from the binding of the Notch receptor to its ligands in adjacent cells driving cell-to-cell communication. Yet, cell-autonomous control of Notch signaling through both ligand-dependent and ligand-independent mechanisms is known to occur as well. Examples include Notch signaling arising in the absence of ligand binding, and cis-inhibition of Notch signaling by titration of the Notch receptor upon binding to its ligands within a single cell. Increasing experimental evidences support that the binding of the Notch receptor with its ligands within a cell (cis-interactions) can also trigger a cell-autonomous Notch signal (cis-signaling), whose potential effects on cell fate decisions and patterning remain poorly understood. To address this question, herein we mathematically and computationally investigate the cell states arising from the combination of cis-signaling with additional Notch signaling sources, which are either cell-autonomous or involve cell-to-cell communication. Our study shows that cis-signaling can switch from driving cis-activation to effectively perform cis-inhibition and identifies under which conditions this switch occurs. This switch relies on the competition between Notch signaling sources, which share the same receptor but differ in their signaling efficiency. We propose that the role of cis-interactions and their signaling on fine-grained patterning and cell fate decisions is dependent on whether they drive cis-inhibition or cis-activation, which could be controlled during development. Specifically, cis-inhibition and not cis-activation facilitates patterning and enriches it by modulating the ratio of cells in the high-ligand expression state, by enabling additional periodic patterns like stripes and by allowing localized patterning highly sensitive to the precursor state and cell-autonomous bistability. Our study exemplifies the complexity of regulations when multiple signalng sources share the same receptor and provides the tools for their characterization.

On the effects of welding parameters on weld quality of plasma arc keyhole welding of structural steels

The possibility and the usefulness of applying plasma keyhole welding to structural steels with different compositions and material thicknesses, and in various welding positions has been examinated. Single pass butt welding with I groove in flat, horizontal vertical and vertical positions and root welding with V , Y and U grooves of thick plate material in flat position have been studied and the welds with high quality has been obtained. The technological conditions for successful welding are presented. The single and interactive effects of welding parameters on weld quality, especially on surface weld defects, geometrical form errors, internal defects and mechanical properties (strength, ductility, impact toughness, hardness and bendability) of weld joint, are presented. Welding parameter combinations providing the best quality welds are also presented.

The effects of real time control of welding parameters on weld quality in plasma arc keyhole welding

Joints intended for welding frequently show variations in geometry and position, for which it is unfortunately not possible to apply a single set of operating parameters to ensure constant quality. The cause of this difficulty lies in a number of factors, including inaccurate joint preparation and joint fit up, tack welds, as well as thermal distortion of the workpiece. In plasma arc keyhole welding of butt joints, deviations in the gap width may cause weld defects such as an incomplete weld bead, excessive penetration and burn through. Manual adjustment of welding parameters to compensate for variations in the gap width is very difficult, and unsatisfactory weld quality is often obtained. In this study a control system for plasma arc keyhole welding has been developed and used to study the effects of the real time control of welding parameters on gap tolerance during welding of austenitic stainless steel AISI 304L. The welding tests demonstrated the beneficial effect of real time control on weld quality. Compared with welding using constant parameters, the maximum tolerable gap width with an acceptable weld quality was 47% higher when using the real time controlled parameters for a plate thickness of 5 mm. In addition, burn through occurred with significantly larger gap widths when parameters were controlled in real time. Increased gap tolerance enables joints to be prepared and fit up less accurately, saving time and preparation costs for welding. In addition to the control system, a novel technique for back face monitoring is described in this study. The test results showed that the technique could be successfully applied for penetration monitoring when welding non magnetic materials. The results also imply that it is possible to measure the dimensions of the plasma efflux or weld root, and use this information in a feedback control system and, thus, maintain the required weld quality.

Size Effect and Notch Size Effect in Metal Fatigue

It is a well known phenomenon that the constant amplitude fatigue limit of a large component is lower than the fatigue limit of a small specimen made of the same material. In notched components the opposite occurs: the fatigue limit defined as the maximum stress at the notch is higher than that achieved with smooth specimens. These two effects have been taken into account in most design handbooks with the help of experimental formulas or design curves. The basic idea of this study is that the size effect can mainly be explained by the statistical size effect. A component subjected to an alternating load can be assumed to form a sample of initiated cracks at the end of the crack initiation phase. The size of the sample depends on the size of the specimen in question. The main objective of this study is to develop a statistical model for the estimation of this kind of size effect. It was shown that the size of a sample of initiated cracks shall be based on the stressed surface area of the specimen. In case of varying stress distribution, an effective stress area must be calculated. It is based on the decreasing probability of equally sized initiated cracks at lower stress level. If the distribution function of the parent population of cracks is known, the distribution of the maximum crack size in a sample can be defined. This makes it possible to calculate an estimate of the largest expected crack in any sample size. The estimate of the fatigue limit can now be calculated with the help of the linear elastic fracture mechanics. In notched components another source of size effect has to be taken into account. If we think about two specimens which have similar shape, but the size is different, it can be seen that the stress gradient in the smaller specimen is steeper. If there is an initiated crack in both of them, the stress intensity factor at the crack in the larger specimen is higher. The second goal of this thesis is to create a calculation method for this factor which is called the geometric size effect. The proposed method for the calculation of the geometric size effect is also based on the use of the linear elastic fracture mechanics. It is possible to calculate an accurate value of the stress intensity factor in a non linear stress field using weight functions. The calculated stress intensity factor values at the initiated crack can be compared to the corresponding stress intensity factor due to constant stress. The notch size effect is calculated as the ratio of these stress intensity factors. The presented methods were tested against experimental results taken from three German doctoral works. Two candidates for the parent population of initiated cracks were found: the Weibull distribution and the log normal distribution. Both of them can be used successfully for the prediction of the statistical size effect for smooth specimens. In case of notched components the geometric size effect due to the stress gradient shall be combined with the statistical size effect. The proposed method gives good results as long as the notch in question is blunt enough. For very sharp notches, stress concentration factor about 5 or higher, the method does not give sufficient results. It was shown that the plastic portion of the strain becomes quite high at the root of this kind of notches. The use of the linear elastic fracture mechanics becomes therefore questionable.

Moottoripyörän rungon muuntelun valvontakriteerit muutoskatsastuksessa

Muutoskatsastusta koskeva lainsäädäntö aiheuttaa tulkintavaikeuksia ja rajoitteita moottoripyöräharrastajille ja alan toimijoille. Nykyinen asetus edellyttää tarvittaessa asiantuntijaselvitystä rakennemuutoksen lujuudesta ja hitsaustyöstä. Moottoripyörän geometria on laissa rajattu akselivälin ja emäputken kulman osalta. Moottoripyörien runkoja valmistetaan hitsaamalla seostamattomista teräksistä ja lämpökäsiteltävistä alumiini- ja terässeoksista. Runkojen muuntelu suoritetaan myös yleisesti hitsaamalla. Turvallisuuden kannalta tärkeiltä hitsausliitoksilta vaaditaan hyvää laatua, joka saavutetaan oikeilla hitsausparametreilla ja -suorituksella. Vaatimukset seostamattomalle teräkselle voidaan täyttää pätevöityneen hitsaajan toimesta. Lämpökäsiteltävät seokset vaativat lisäksi jälkilämpökäsittelyn, mikä edelleen vaikeuttaa runkojen hitsausta. Hitsien laadun merkitystä moottoripyörän rungossa tutkittiin soveltamalla rajoitetun vahingon periaatetta. Vauriotapauksena mallinnettiin satunnaisen rungon hitsausliitoksen murtuminen. Eri kuormitustilanteissa elementtimenetelmää hyödyntäen todettiin chopper-tyyppisten moottoripyörien runkojen olevan osittain vauriosietoisia ja havaittiin kriittiset hitsausliitokset emä- ja vaakaputken alueilla. Moottoripyörien runkojen kriittisiä hitsausliitoksia tarkasteltiin väsymisen kannalta. Soveltamalla tehollista lovijännitystä, vertailtiin emäputken hitsausliitosten väsymiskestävyyttä oletetulla kuormituksella. Tulosten perusteella muunneltu moottoripyörän runko voi olla alkuperäisrunkoa kestävämpi tai heikompi. Moottoripyörän akseliväli tai emäputken kulma eivät määrää kestävyyttä, vaan rakenteen yksityiskohtainen suunnittelu. Kriittisten liitosten väsymiskestävyyksissä havaittiin merkittäviä eroja eri mallien välillä.

Trolley R&D project for a small portal log yard crane

This master’s thesis was done for Andritz Inc. Atlanta Georgia. The purpose of the thesis was to develop a new trolley for a small portal log yard crane. In the beginning of the thesis the basic principles of the systematic design processes have been described, along which the design work of the trolley has proceeded. The second literature part consists of the design and dimensioning of the welded steel structures under fatigue loading. The design work of the trolley consists of the engineering and the selection of the mechanical components and the design of the load carrying structure for the trolley. The realization of the steel structure of the trolley is based on the fatigue and static dimensioning. The fatigue dimensioning is grounded in the life expectations estimated for the trolley and the static dimensioning is based on the CMAA guidelines. The computer aided element method was utilized in the design of the steel structure. The effective notch method and the hot spot method were used in the fatigue calculations. The trolley structure was carried out by using the sheet metal parts in order to manufacture the structure as effective and low cost way as possible. The corner stone of the dimensioning of the trolley structure was the utilization of the open profiles made of welded or cold formed sheet metals, which provide better weldability, weld inspection, access for repairs and corrosion protection. As a last part of the thesis a new trolley traveling system was developed. The distribution of the wheel loads of the trolley bogies on the main girder was also studied, which led to an innovative suspension arrangement between the trolley leg and the bogie. The new bogie solution increases the service life of the main girder of the crane and improves the stability of the bogies. The outcome of the thesis is an excellent trolley structure from the weight and the service life point of view.

Väsymiskestävyyden määritys murtumismekaanisilla särönmallinnusohjelmilla

Tässä työssä tutkitaan Wärtsilä Oyj:n moottorin ja ABB Oy:n generaattorin muodostaman aggregaatin väsymiskestävyyttä lineaarisen murtumismekaniikan avulla. Työn tavoitteena on selvittää ABAQUS/XFEM- ja FRANC3D-ohjelman soveltuvuus kuormitukseltaan ja geometrialtaan vaativan generaattorirungon suunnittelutyökaluksi. Generaattorirungon kuormitukset aiheutuvat aggregaatin käynnin sekä käynnistys- ja sammutusvaiheen aikai-sista syntyvistä värähtelyistä. Tutkimuksessa tarkastellaan generaattorirungon väsymistä käynninaikaisella kuormituksella. Työssä mallinnettiin generaattorirungosta valittu hitsausdetalji alimallinnustekniikalla, jolloin alimallin reunaehdot voitiin määrittää aggregaatille tehdyn vastelaskennan perus-teella. Alimallista tutkittiin kahta erilaista hitsiliitostyyppiä, joihin mallinnettiin XFEM- ja FRANC3D-ohjelmilla erikokoisia säröjä hitsiliitosten rajaviivalle sekä juuren puolelle. Tutkittavilla ohjelmilla saatujen jännitysintensiteettikertoimien avulla säröille voitiin las-kea ekvivalentti jännitysintensiteettikerroin, jota verrattiin kokeellisesti saatuun jännitysin-tensiteettikertoimen kynnysarvoon. XFEM- ja FRANC3D-ohjelmia vertailtiin käytön helppouden, tulosten tarkkuuden sekä laskenta-aikojen perusteella. Käytettävyyden ja laskenta-aikojen perusteella XFEM-ohjelma soveltui paremmin käytettäväksi teollisuudessa suunnittelu- ja kehitystyön apu-työkaluna. FRANC3D taas antoi XFEM-ohjelmaa luotettavampia tuloksia, mutta laskenta-ajat olivat moninkertaiset.

FAT-luokkien määritys hitsatuille levyliitoksille käyttämällä lineaarisen murtumismekaniikan särönkasvun simulointia

Työssä tutkittiin hitsattujen levyliitosten väsymiskestävyyden mitoitusarvoja. Hitsien väsymiskestävyyden mitoitusarvot määritettiin lineaarista murtumismekaniikkaa soveltavalla 2D FEM-laskentaohjelmalla. Murtumismekaanisen laskennan tuloksista määriteltiin, eri liitosgeometrioiden ja kuormitustyyppien mukaisia, nimellisen jännityksen väsymismitoitusmenetelmää vastaavia FAT-luokkia, joissa on huomioitu rakenteellinen jännitys hitsiä vastaan kohtisuorassa suunnassa. Tutkittujen liitosten geometriat olivat pääsääntöisesti poikkeavia mitoitusstandardien ja ohjeiden sisältämistä taulukkotapauksista. Laskennassa otettiin huomioon hitsien liittymiskulma perusaineeseen, rajaviivan pyöristykset ja vajaa hitsautumissyvyys. Kuormitustyyppien vaihtelua tutkittiin rakenteellisen jännityksen taivutusosuuden muutoksilla ja kuormaa kantavien X-liitosten risteävien kuormituksien suhteellisilla suuruuksilla. Väsymiskestävyydet määritettiin kuormituskohtaisille kalvo- ja taivutusjännityksille sekä näiden jännitysjakaumien keskiarvoille. Työssä saatuja FAT-luokkia voidaan hyödyntää vastaavien geometrioiden ja kuormitusten yhteydessä, sekä interpoloimalla myös tuloksien väliarvoissa. Työssä käytetyillä menetelmillä voidaan parantaa nimellisen jännityksen mitoitusmenetelmän tarkkuutta ja laajentaa sitä koskemaan myös taulukkotapausten ulkopuolisia liitoksia. Työn tuloksissa on esitetty FAT-luokkia T-, X- ja päittäisliitoksille ja näiden eri kuormitusyhdistelmille.

Eri MAG-hitsausprosessien ja -parametrien vaikutus suurlujuusteräksestä valmistetun otsapienahitsin äärikestävyyteen, muodonmuutoskykyyn ja vauriomuotoon

Työssä tutkittiin Ruukki Oyj:n suorasammutetusta S960QC-teräksestä valmistetun kuormaakantavan levyjen ristiliitoksen pienahitsien lujuutta, muodonmuutoskykyä ja vaurioitumismekanismia laajaan kokeelliseen aineistoon perustuen. Tärkeimpänä muuttujana koematriisissa olivat eri MAG-hitsausprosessit. Perinteisen kuumakaarihitsauksen vertailukohteena oli Kemppi Oy:n uusi adaptiivinen valokaaren pituutta säätävä WiseFusion-hitsaustoiminto kuuma- ja pulssikaarihitsauksessa. Näiden kolmen hitsausprosessin rinnalla varioitiin erisuuruisia a-mittoja, eri hitsauslisäaineita ja hitsin erikylkisyyttä. Lisäksi juuritunkeuman estämisen vaikutusta hitsien käyttäytymiseen tutkittiin täydentävällä koesarjalla, jossa tunkeuman muodostuminen estettiin levyjen väliin asetetulla volframilevyllä. Työn perimmäisenä tavoitteena oli selvittää syy aiemmassa tutkimuksessa havaitulle pienahitsien vaurioitumiselle leikkautumalla sularajaa pitkin. Sularajan suhteellista pituutta saadaan kasvatettua estämällä hitsin juuritunkeuma ja absoluuttista pituutta saadaan lisää kateettipoikkeaman avulla. Lisäksi tutkimuksessa oli tarkoitus tuoda esille suurlujuusteräksisen liitoksen eri mitoituslähtökohdat (mm. lämmöntuonnin kontrollointi). Tämän vuoksi hitsausparametrit mitattiin jännitteen ja virran hetkellisiin arvoihin perustuen, jolloin kuuma- ja pulssikaarihitsauksen laskennalliset hitsaustehot ovat vertailukelpoisia. Koehitseistä valmistettiin hieet hitsien tarkan geometrian määrittämiseksi ja liitoksen mekaaniset ominaisuudet tutkittiin vetokokeella. Tulosten perusteella sularajavaurio aktivoituu pulssikaarella hitsatuissa koekappaleissa. Tämä aiheutunee pulssi- ja kuumakaarihitsauksen sularajan mikrorakenteiden eroavaisuudesta. Sularajavaurio näyttää huonontavan hitsien muodonmuutoskykyä, mutta jatkokokeita tuloksen verifioimiseksi on tehtävä. S960QC-teräkselle ominaisen pehmenneen vyöhykkeen vaurio ei aktivoitunut, vaikka Ruukin antamat jäähtymisaikasuositukset ylitettiin reilusti.