Repair Welding Effects on the Bending Fatigue Strength of AISI 4130 Aeronautical Steel used in a Critical to the Flight-Safety Structure

The aim of this study was to analyze the effect of successive TIG (tungsten inert gas) welding repairs on the reverse bending fatigue strength of AISI 4130 steel, which is widely used in components critical to the flight-safety. In order to simulate the abrupt maneuvers, wind bursts, motor vibration and helixes efforts, which generate cyclic bending loadings at the welded joints of a specific aircraft component called motor cradle, experimental reverse bending fatigue tests were carried out on specimens made from hot-rolled steel plate, 1.10 mm (0.043 in) thick, by mean of a SCHENK PWS equipment, with load ratio R = -1, under constant amplitude, at 30 Hz frequency and room temperature. It was observed that the bending fatigue strength decreases after the TIG (Tungsten Inert Gas) welding process application on AISI 4130 steel, with subsequent decrease due to re-welding sequence as well. Microstructural analyses and microhardness measurements on the base material, heat-affected zone (HAZ) and weld metal, as well as the effects of the weld bead geometry on the obtained results, have complemented this study.

Fatigue apparatus for geometrically complex non-standardized specimens

Standard Test Methods (e.g. ASTM, DIN) for materials characterization in general, and for fatigue in particular, do not contemplate specimens with complex geometries, as well as the combination of axial and in-plane bending loads in their methodologies. The present study refers to some patents and the new configuration or configurations of specimens (non-standardized by the status quo of test methods) and a device developed to induce axial and bending combined forces resultants from axial loads applied by any one test equipment (dynamic or monotonic) which possesses such limitation, towards obtaining more realistic results on the fatigue behavior, or even basic mechanical properties, from geometrically complex structures. Motivated by a specific and geometrically complex aeronautic structure (motor-cradle), non-standardized welded tubular specimens made from AISI 4130 steel were fatigue-tested at room temperature, by using a constant amplitude sinusoidal load of 20 Hz frequency, load ratio R = 0.1 with and without the above referred auxiliary fatigue apparatus. The results showed the fatigue apparatus was efficient for introducing higher stress concentration factor at the welded specimen joints, consequently reducing the fatigue strength when compared to other conditions. From the obtained results it is possible to infer that with small modifications the proposed apparatus will be capable to test a great variety of specimen configurations such as: squared tubes and plates with welded or melted junctions, as well as other materials such as aluminum, titanium, composites, polymeric, plastics, etc. © 2009 Bentham Science Publishers Ltd.

Modelos sin malla en simulación numérica de estructuras aeroespaciales

La presente Tesis Doctoral aborda la introducción de la Partición de Unidad de Bernstein en la forma débil de Galerkin para la resolución de problemas de condiciones de contorno en el ámbito del análisis estructural. La familia de funciones base de Bernstein conforma un sistema generador del espacio de funciones polinómicas que permite construir aproximaciones numéricas para las que no se requiere la existencia de malla: las funciones de forma, de soporte global, dependen únicamente del orden de aproximación elegido y de la parametrización o mapping del dominio, estando las posiciones nodales implícitamente definidas. El desarrollo de la formulación está precedido por una revisión bibliográfica que, con su punto de partida en el Método de Elementos Finitos, recorre las principales técnicas de resolución sin malla de Ecuaciones Diferenciales en Derivadas Parciales, incluyendo los conocidos como Métodos Meshless y los métodos espectrales. En este contexto, en la Tesis se somete la aproximación Bernstein-Galerkin a validación en tests uni y bidimensionales clásicos de la Mecánica Estructural. Se estudian aspectos de la implementación tales como la consistencia, la capacidad de reproducción, la naturaleza no interpolante en la frontera, el planteamiento con refinamiento h-p o el acoplamiento con otras aproximaciones numéricas. Un bloque importante de la investigación se dedica al análisis de estrategias de optimización computacional, especialmente en lo referente a la reducción del tiempo de máquina asociado a la generación y operación con matrices llenas. Finalmente, se realiza aplicación a dos casos de referencia de estructuras aeronáuticas, el análisis de esfuerzos en un angular de material anisotrópico y la evaluación de factores de intensidad de esfuerzos de la Mecánica de Fractura mediante un modelo con Partición de Unidad de Bernstein acoplada a una malla de elementos finitos. ABSTRACT This Doctoral Thesis deals with the introduction of Bernstein Partition of Unity into Galerkin weak form to solve boundary value problems in the field of structural analysis. The family of Bernstein basis functions constitutes a spanning set of the space of polynomial functions that allows the construction of numerical approximations that do not require the presence of a mesh: the shape functions, which are globally-supported, are determined only by the selected approximation order and the parametrization or mapping of the domain, being the nodal positions implicitly defined. The exposition of the formulation is preceded by a revision of bibliography which begins with the review of the Finite Element Method and covers the main techniques to solve Partial Differential Equations without the use of mesh, including the so-called Meshless Methods and the spectral methods. In this context, in the Thesis the Bernstein-Galerkin approximation is subjected to validation in one- and two-dimensional classic benchmarks of Structural Mechanics. Implementation aspects such as consistency, reproduction capability, non-interpolating nature at boundaries, h-p refinement strategy or coupling with other numerical approximations are studied. An important part of the investigation focuses on the analysis and optimization of computational efficiency, mainly regarding the reduction of the CPU cost associated with the generation and handling of full matrices. Finally, application to two reference cases of aeronautic structures is performed: the stress analysis in an anisotropic angle part and the evaluation of stress intensity factors of Fracture Mechanics by means of a coupled Bernstein Partition of Unity - finite element mesh model.

Análise numérica e experimental de juntas aeronáuticas rebitadas sob solicitação estática.

Uniões por prendedores são elementos amplamente utilizados na indústria aeronáutica para a união de partes constituintes da aeronave. Contudo, devido à sua geometria e aos carregamentos sofridos, estes elementos estão frequentemente sujeitos a falhas por fadiga. Assim, para um projeto e dimensionamento bem executado dessas juntas, é necessário conhecer seu comportamento mecânico e o campo de tensões ao qual estão sujeitas. O método dos elementos finitos certamente atende a estas necessidades; porém, o uso de elementos sólidos tridimensionais para a representação destas uniões pode levar a análises demasiadamente demoradas e custosas, sendo desejável o uso de modelos mais simplificados. Nesse trabalho, juntas de topo assimétricas são modeladas pelo método dos elementos finitos, utilizando tanto elementos sólidos tridimensionais quanto elementos de casca, com o objetivo de encontrar um modelo relativamente simples que apresente resultados satisfatórios e requeira um menor tempo de solução. Os resultados numéricos obtidos são comparados com resultados experimentais, que utilizam extensômetros e fotoelasticidade.

Fatigue Behavior of Weld Repaired AISI 4130 Aeronautic Steel Used in Critical Flight Safety Structures

Since the 1950s, fatigue is the most important project and operational consideration for both civil and military aircrafts. For some aircraft models the most loaded component is one that supports the motor: the Motor Cradle. Because they are considered critical to the flight safety the aeronautic standards are extremely rigorous in manufacturing them by imposing a zero index of defects on the final weld quality (Safe Life), which is 100% inspected by Non-Destructive Testing/NDT. This study has as objective to evaluate the effects of up to four successive TIG welding repairs on the axial fatigue strength of an AISI 4130 steel. Tests were conducted on hot-rolled steel plate specimens, 0.89 mm thick, with load ratio R = 0.1, constant amplitude, at 20 Hz frequency and in room temperature, in accordance with ASTM E466 Standard. The results were related to microhardness and microstructural and geometric changes resulting from welding cycles.