Fractografia quantitativa: correlação entre dimensão fractal e tenacidade à fratura em compósitos fibra de carbono/epóxi

The fracture surfaces express the sequence of events of energy release due to crack propagation by linking the relief of the fracture to the loading stresses. This study aims to evaluate the heterogeneity of the critical zone for the advancement of the crack along its entire length in a thermoset composite carbon fiber and epoxy matrix, fractured in DCB testing (Double Cantilever Beam) and ENF (End-Notched Flexure). Investigations were made from image stacks obtained by optical reflection of extended depth from focus reconstruction. The program NIH Image J was used to obtain elevation map and fully focused images of the fracture surface, whose topographies were quantitatively analyzed. The monofractal behavior for DCB samples was assessed as being heterogeneous along the crack front and along the crack for all the conditionings. For the samples fractured in ENF test, there was a strong positive correlation to the natural condition, considering the fibers at 0° for the monofractal dimension and structural dimension (Df and Ds). For fibers at 90° to crack propagation, there was a moderate positive correlation for the textural dimension of natural condition. However, for the samples under ultraviolet condition and those subjected to thermal cycles, there was no correlation between the fractal dimension and fracture toughness in mode II

Estudo da propagação de trinca por fadiga sob carregamento de amplitude variável

For engineering projects that require high reliability levels, is often not enough know only physical and chemical material properties. It’s necessary understand the failure mode of these materials in operation to ensure security level in the project and establish more stringent criteria in the analysis of structural integrity. Due to this need, aircraft industry has been using aluminum alloys in their designs and projects. “Currently more than 70% of aircraft structures are built of high strength aluminum alloys among which stand out 7075-T6 and 2024-T3 alloys, which are considered basics for being used in the new alloys development.” (PASTOUKHOV & VOORWALD, 1995). Some years ago ALCOA develops Al 2524 alloy that has emerged as refinement of Al 2024 (Al, Cu. Mg) alloy, with purpose of improve fracture toughness and fatigue resistance on structural components. The present research addresses testing of fatigue crack propagation under variable amplitude loading for Al 2024 alloy, observing the interaction effects from application of overhead blocks and plastic zone at the crack tip and makes an analysis of fracture surface images

Comportamento fractal de superfícies de fadiga em ligas aeronaúticas

Fracture surfaces express sequences of events of energy release with crack propagation in metal alloys, the evolution of topographic features can indicate the lines of load action, failures during the use or processing. The quantitative fractography is an important tool in the study of fracture surfaces, because it allows their interpretation and characterization. In order to evaluate the effectiveness of the characterization of fracture surfaces grounded on concepts such as selfsimilarity and self-affinity, it used the 15-5PH steel that was characterized by metallographic and tensile tests. The metallography allows the microstructural characterization of this steel and proved the presence of the martensite phase in the slats form and a fine-grained, both in the radial and in the axial direction of the dowel. The tensile test (ASTM E8) of this material allowed the determination of the mechanical properties, so based on the obtained results it was possible to affirm that the 15-5PH steel has high mechanical properties and a good stretch. Besides, the specimens also underwent testing of crack propagation, standardized by ASTM E647-00, thus it was obtained the fracture surfaces for characterization under monofractal and multifractal approaches. In front of all the exposed it was possible to conclude that in all measurements the correlation between the crack tip position and the fractal dimension was established in accordance with changes in the thickness and in the fracture micromechanisms presents. Furthermore, the multifractal approach was more sensitive to these variations allowing a more detailed characterization of the morphology

Fractografia quantitativa e o conceito de tenacidade à fratura para a análise do efeitodo choque térmicos em TiO2

The present study evaluated the use of semicircular bending test (SCB) as an alternative to conventional bending test to examine the effect of thermal shock. Still, studies the behavior of fracture surfaces generated by monofractal behavior analysis, which allows us to evaluate the contributions of the microstructure and the mechanical context in forming reliefs during the crack propagation. The fractal analysis is made from elevation maps obtained by reconstruction method by extension of the focus stacks of digital images acquired in microscope. The specimens used were samples semicircular pressed TiO2 (rutile) with and without heat shock, prepared for testing mode I loading. Were also produced, specimens in the form of bars for Weibull statistical analysis. From the three-point bending test, we found the variation of fracture toughness between the samples after the heat shock and natural condition. The SCB test was feasible for the analysis of thermal shock resistance. The results showed that the value of the fracture toughness decreases as the heat shock treatment

Estudo do efeito do processo de shot peening na taxa de propagação de trinca por fadiga na liga aeronáutica 2024 - T3

Pós-graduação em Engenharia Mecânica - FEG

Fadiga em compósitos 5HS carbono/epóxi processados via RTM: relação entre cargas axiais no plano e modos de delaminação

Pós-graduação em Engenharia Mecânica - FEG

A influência do tamanho de grão ferrítico da peça na integridade superficial de peças erodidas

Pós-graduação em Engenharia Mecânica - FEIS

Comportamento biomecânico de estruturas multicamadas em restaurações protéticas

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Predicting the behaviour of structures under impact loads using geometrically distorted scaled models

When a scaled structure (model or replica) is used to predict the response of a full-size compound (prototype), the model geometric dimensions should relate to the corresponding prototype dimensions by a single scaling factor. However, owing to manufacturing technical restrictions, this condition cannot be accomplished for some of the dimensions in real structures. Accordingly, the distorted geometry will not comply with the overall geometric scaling factor, infringing the Pi theorem requirements for complete dynamic similarity. In the present study, a method which takes geometrical distortions into account is introduced, leading to a model similar to the prototype. As a means to infer the performance of this method, three analytical problems of structures subjected to dynamic loads are analysed. It is shown that the replica developed applying this technique is able to accurately predict the full-size structure behaviour even when the studied models have some of their dimensions severely distorted. (C) 2012 Elsevier Ltd. All rights reserved.

Subcritical fatigue in fuse networks

We obtain the Paris law of fatigue crack propagation in a fuse network model where the accumulated damage in each resistor increases with time as a power law of the local current amplitude. When a resistor reaches its fatigue threshold, it burns irreversibly. Over time, this drives cracks to grow until the system is fractured into two parts. We study the relation between the macroscopic exponent of the crack-growth rate -entering the phenomenological Paris law-and the microscopic damage accumulation exponent, gamma, under the influence of disorder. The way the jumps of the growing crack, Delta a, and the waiting time between successive breaks, Delta t, depend on the type of material, via gamma, are also investigated. We find that the averages of these quantities, <Delta a > and <Delta t >/< t(r)>, scale as power laws of the crack length a, <Delta a > proportional to a(alpha) and <Delta t >/< t(r)> proportional to a(-beta), where < t(r)> is the average rupture time. Strikingly, our results show, for small values of gamma, a decrease in the exponent of the Paris law in comparison with the homogeneous case, leading to an increase in the lifetime of breaking materials. For the particular case of gamma = 0, when fatigue is exclusively ruled by disorder, an analytical treatment confirms the results obtained by simulation. Copyright (C) EPLA, 2012

Bonded structures for enhanced damage tolerant pressurized fuselages

Adhesive bonding provides solutions to realize cost effective and low weight aircraft fuselage structures, in particular where the Damage Tolerance (DT) is the design criterion. Bonded structures that combine Metal Laminates (MLs) and eventually Selective Reinforcements can guarantee slow crack propagation, crack arrest and large damage capability. To optimize the design exploiting the benefit of bonded structures incorporating selective reinforcement requires reliable analysis tools. The effect of bonded doublers / selective reinforcements is very difficult to be predicted numerically or analytically due to the complexity of the underlying mechanisms and failures modes acting. Reliable predictions of crack growth and residual strength can only be based on sound empirical and phenomenological considerations strictly related to the specific structural concept. Large flat stiffened panels that combine MLs and selective reinforcements have been tested with the purpose of investigating solutions applicable to pressurized fuselages. The large test campaign (for a total of 35 stiffened panels) has quantitatively investigated the role of the different metallic skin concepts (monolithic vs. MLs) of the aluminum, titanium and glass-fiber reinforcements, of the stringers material and cross sections and of the geometry and location of doublers / selective reinforcements. Bonded doublers and selective reinforcements confirmed to be outstanding tools to improve the DT properties of structural elements with a minor weight increase. However the choice of proper materials for the skin and the stringers must be not underestimated since they play an important role as well. A fuselage structural concept has been developed to exploit the benefit of a metal laminate design concept in terms of high Fatigue and Damage Tolerance (F&DT) performances. The structure used laminated skin (0.8mm thick), bonded stringers, two different splicing solutions and selective reinforcements (glass prepreg embedded in the laminate) under the circumferential frames. To validate the design concept a curved panel was manufactured and tested under loading conditions representative of a single aisle fuselage: cyclic internal pressurization plus longitudinal loads. The geometry of the panel, design and loading conditions were tailored for the requirements of the upper front fuselage. The curved panel has been fatigue tested for 60 000 cycles before the introduction of artificial damages (cracks in longitudinal and circumferential directions). The crack growth of the artificial damages has been investigated for about 85 000 cycles. At the end a residual strength test has been performed with a “2 bay over broken frame” longitudinal crack. The reparability of this innovative concept has been taken into account during design and demonstrated with the use of an external riveted repair. The F&DT curved panel test has confirmed that a long fatigue life and high damage tolerance can be achieved with a hybrid metal laminate low weight configuration. The superior fatigue life from metal laminates and the high damage tolerance characteristics provided by integrated selective reinforcements are the key concepts that provided the excellent performances. The weight comparison between the innovative bonded concept and a conventional monolithic riveted design solution showed a significant potential weight saving but the weight advantages shall be traded off with the additional costs.

Fracture Mechanics Investigation of Structures with Defects

Fracture mechanics plays an important role in the material science, structure design and industrial production due to the failure of materials and structures are paid high attention in human activities. This dissertation, concentrates on some of the fractural aspects of shaft and composite which have being increasingly used in modern structures, consists four chapters within two parts. Chapters 1 to 4 are included in part 1. In the first chapter, the basic knowledge about the stress and displacement fields in the vicinity of a crack tip is introduced. A review involves the general methods of calculating stress intensity factors are presented. In Chapter 2, two simple engineering methods for a fast and close approximation of stress intensity factors of cracked or notched beams under tension, bending moment, shear force, as well as torque are presented. New formulae for calculating the stress intensity factors are proposed. One of the methods named Section Method is improved and applied to the three dimensional analysis of cracked circular section for calculating stress intensity factors. The comparisons between the present results and the solutions calculated by ABAQUS for single mode and mixed mode are studied. In chapter 3, fracture criteria for a crack subjected to mixed mode loading of two-dimension and three-dimension are reviewed. The crack extension angle for single mode and mixed mode, and the critical loading domain obtained by SEDF and MTS are compared. The effects of the crack depth and the applied force ratio on the crack propagation angle and the critical loading are investigated. Three different methods calculating the crack initiation angle for three-dimension analysis of various crack depth and crack position are compared. It should be noted that the stress intensity factors used in the criteria are calculated in section 2.1.

Numerical simulations of the effects of residual stresses in adhesively bonded composite specimen

In this work the problem of performing a numerical simulation of quasi-static crack propagation within an adhesive layer of a bonded joint under Mode I loading affected by stress field changes due to thermal-chemical shrinkage induced by cure process is addressed. Secondly, a parametric study on fracture critical energy, cohesive strength and Young's modulus is performed. Finally, a particular case of adhesive layer stiffening is simulated in order to verify qualitatively the major effect.

Numerical modeling of the failure mechanisms in Si thin film anode for Li-ion batteries

In recent times, the demand for the storage of electrical energy has grown rapidly for both static applications and the portable electronics enforcing the substantial improvement in battery systems, and Li-ion batteries have been proven to have maximum energy storage density in all rechargeable batteries. However, major breakthroughs are required to consummate the requirement of higher energy density with lower cost to penetrate new markets. Graphite anode having limited capacity has become a bottle neck in the process of developing next generation batteries and can be replaced by higher capacity metals such as Silicon. In the present study we are focusing on the mechanical behavior of the Si-thin film anode under various operating conditions. A numerical model is developed to simulate the intercalation induced stress and the failure mechanism of the complex anode structure. Effect of the various physical phenomena such as diffusion induced stress, plasticity and the crack propagation are investigated to predict better performance parameters for improved design.

Daily and seasonal thermal stresses in tilings: a field survey combined with numeric modeling

This study investigates thermally induced tensile stresses in ceramic tilings. Daily and seasonal thermal cycles, as well as, rare but extreme events, such as a hail-storm striking a heated terrace tiling, were studied in the field and by numerical modeling investigations. The field surveys delivered temperature– time diagrams and temperature profiles across tiling systems. These data were taken as input parameters for modeling the stress distribution in the tiling system in order to detect potential sites for material failure. Dependent on the thermal scenario (e.g., slow heating of the entire structure during morning and afternoon, or a rapid cooling of the tiles by a rain storm) the modeling indicates specific locations with high tensile stresses. Typically regions along the rim of the tiling field showed stresses, which can become critical with respect to the adhesion strength. Over the years, ongoing cycles of thermal expansion–contraction result in material fatigue promoting the propagation of cracks. However, the installation of flexible waterproofing membranes (applied between substrate and tile adhesive) represents an efficient technical innovation to reduce such crack propagation as confirmed by both numerical modeling results and microstructural studies on real systems.