A FEM-based model to study the behaviour of corroded RC beams shear repaired by NSM CFRP rods technique

This paper presents the main features of finite element FE numerical model developed using the computer code FEMIX to predict the near-surface mounted NSM carbon-fiber-reinforced polymer CFRP rods shear repair contribution to corroded reinforced concrete RC beams. In the RC beams shear repaired with NSM technique, the Carbon Fibre Reinforced Polymer (CFRP) rods are placed inside pre-cut grooves onto the concrete cover of the RC beam’s lateral faces and are bonded to the concrete with high epoxy adhesive. Experimental and 3D numerical modelling results are presented in this paper in terms of load-deflection curves, and failure modes for 4 short corroded beams: two corroded beams (A1CL3-B and A1CL3-SB) and two control beams (A1T-B and A1T-SB), the beams noted with B were let repaired in bending only with NSM CFRP rods while the ones noted with SB were repaired in both bending and shear with NSM technique. The corrosion of the tensile steel bars and its effect on the shear capacity of the RC beams was discussed. Results showed that the FE model was able to capture the main aspects of the experimental load-deflection curves of the RC beams, moreover it has presented the experimental failure modes and FE numerical modelling crack patterns and both gave similar results for non-shear repaired beams which failed in diagonal tension mode of failure and for shear-repaired beams which failed due to large flexural crack at the middle of the beams along with the concrete crushing, three dimensional crack patterns were produced for shear-repaired beams in order to investigate the splitting cracks occurred at the middle of the beams and near the support.

Thin panels of cement composites reinforced with recycled fibres for the shear strengthening of reinforced concrete elements

A new technique was developed for producing thin panels of a cement based material reinforced with relatively high content of steel fibres originated from the industry of tyre recycling. Flexural tests with notched and un-notched specimens were carried out to characterize the mechanical properties of this Fibre Reinforced Cement Composite (FRCC) and the results are presented and discussed. The values of the fracture mode I parameters of the developed FRCC were determined by performing inverse analysis with test results obtained in three point notched beam bending tests. To appraise the potentialities of these FRCC panels for the increase of the shear capacity of reinforced (RC) beams, numerical research was performed on the use of developed FRCC panel for shear reinforcement by applying the panels in the lateral faces of RC beams deficiently reinforced in shear.

Exploring the potentialities of a new type of CFRP laminate for the simultaneous flexural and shear strengthening of RC beams: numerical research

This study aims to develop an innovative carbon fibre reinforced polymer (CFRP) laminate with a U configuration to address strengthening interventions, where the increment of both flexural and shear capacity of reinforced concrete (RC) elements is required. This strengthening solution combines the near surface mounted (NSM) and embedded through section (ETS) techniques in the same application, since these techniques have already evidenced high performance on flexural and shear strengthening of RC beams using FRP systems, respectively. In fact, the proposed hybrid technique aims to mobilize the advantages provided by these two strengthening techniques by using an innovative CFRP laminate. The strengthening efficacy of this new hybrid NSM/ETS technique was numerically assessed and compared to the corresponding efficiency of NSM and ETS techniques applied separately for the flexural and shear strengthening of RC beams, respectively. The numerical models are described and the main relevant results are presented and discussed.

Embedded Through-Section shear strengthening technique using steel and CFRP bars in RC beams of different percentage of existing stirrups

The Embedded Through-Section (ETS) technique is a promising technique for the shear strengthening of existing (RC) elements. According to this technique, holes are drilled through the beam section, and bars of steel or FRP material are introduced into these holes and bonded to the concrete with adhesive materials. An experimental program was carried out with RC T-cross section beams strengthened in shear using the ETS steel bars and ETS CFRP rods. The research is focused on the evaluation of the ETS efficiency on beams with different percentage of existing internal transverse reinforcement (ρsw=0.0%, ρsw=0.1% and ρsw=0.17%). The effectiveness of different ETS strengthening configurations was also investigated. The good bond between the strengthening ETS bars and the surrounding concrete allowed the yield initiation of the ETS steel bars and the attainment of high tensile strains in the ETS CFPR rods, leading to significant increase of shear capacity, whose level was strongly influenced by the inclination of the ETS bars and the percentage of internal transverse reinforcement.

A FEM-based model to study the behaviour of corroded RC beams shear repaired by NSM CFRP rods technique

This paper presents the main features of finite element FE numerical model developed using the computer code FEMIX to predict the near-surface mounted NSM carbon-fiber-reinforced polymer CFRP rods shear repair contribution to corroded reinforced concrete RC beams. In the RC beams shear repaired with NSM technique, the Carbon Fibre Reinforced Polymer (CFRP) rods are placed inside pre-cut grooves onto the concrete cover of the RC beam’s lateral faces and are bonded to the concrete with high epoxy adhesive. Experimental and 3D numerical modelling results are presented in this paper in terms of load-deflection curves, failure modes and slip information of the tensile steel bars for 4 short corroded beams: two corroded beams (A1CL3-B and A1CL3-SB) and two control beams (A1T-B and A1T-SB), the beams noted with B were let repaired in bending only with NSM CFRP rods while the ones noted with SB were repaired in both bending and shear with NSM technique. The corrosion of the tensile steel bars and its effect on the shear capacity of the RC beams was discussed. Results showed that the FE model was able to capture the main aspects of the experimental load-deflection curves of the RC beams, moreover it has presented the experimental failure modes and FE numerical modelling crack patterns and both gave similar results for non-shear repaired beams which failed in diagonal tension mode of failure and for shear-repaired beams which failed due to large flexural crack at the middle of the beams along with the concrete crushing, three dimensional crack patterns were produced for shear-repaired beams in order to investigate the splitting cracks occurred at the middle of the beams and near the support.

Design equations for reinforced concrete members strengthened in shear with external FRP reinforcement formulated in an evolutionary multi-objective framework

Methods for predicting the shear capacity of FRP shear strengthened RC beams assume the traditional approach of superimposing the contribution of the FRP reinforcing to the contributions from the reinforcing steel and the concrete. These methods become the basis for most guides for the design of externally bonded FRP systems for strengthening concrete structures. The variations among them come from the way they account for the effect of basic shear design parameters on shear capacity. This paper presents a simple method for defining improved equations to calculate the shear capacity of reinforced concrete beams externally shear strengthened with FRP. For the first time, the equations are obtained in a multiobjective optimization framework solved by using genetic algorithms, resulting from considering simultaneously the experimental results of beams with and without FRP external reinforcement. The performance of the new proposed equations is compared to the predictions with some of the current shear design guidelines for strengthening concrete structures using FRPs. The proposed procedure is also reformulated as a constrained optimization problem to provide more conservative shear predictions.

Evaluation of parameters effective in FRP shear strengthening of RC beams using FE method

Shear strengthening is required when an RC beam is found deficient in shear, or when its shear capacity falls below its flexural capacity after flexural strengthening. A recent technique for the shear strengthening of RC beams is to provide additional FRP web reinforcement, commonly in the form of bonded external FRP strips/sheets. Over the last few years, several experimental studies have been conducted on this new strengthening technique, which has established its effectiveness. While experimental methods of investigation are extremely useful in obtaining information about the composite behaviour of FRP and reinforced concrete, the use of numerical models such as the one presented in this paper helps in developing a good understanding of the behaviour at lower costs. In the study presented in this paper, ANSYS finite element program is used to examine the response of beams strengthened in shear by FRPs. The FE model is calibrated against test results performed at the University of Kentucky. Once validated, the model is used to examine the influence of fibre orientation, compressive strength of concrete, area of tensile and compressive reinforcements, and amount and distance between stirrups on the strength and ductility of FRP strengthened beam.

Assessment of overlay masonry strengthening system under in-plane monotonic and cyclic loading using the diagonal tensile test

The development of novel strengthening techniques to address the seismic vulnerability of masonry elements is gradually leading to simpler, faster and more effective strengthening strategies. In particular, the use of fabric reinforced cementitious matrix systems is considered of great potential, given the increase of ductility achieved with simple and economic strengthening procedures. To assess the effectiveness of these strengthening systems, and considering that the seismic action is involved, one important component of the structural behaviour is the in-plane cyclic response. In this work is discussed the applicability of the diagonal tensile test for the assessment of the cyclic response of strengthened masonry. The results obtained allowed to assess the contribution of the strengthening system to the increase of the load carrying capacity of masonry elements, as well as to evaluate the damage evolution and the stiffness degradation mechanisms developing under cyclic loading.

Reforço ao corte de vigas de betão armado com compósitos de CFRP: valores experimentais vs valores analíticos

Dissertação de mestrado integrado em Engenharia Civil

Impact of Bottom Flange Confinement Reinforcement on Performance of Prestressed Concrete Bridge Girders

For many years AASHTO provided no recommendation to state DOT’s on bottom flange confinement reinforcement for their bridge superstructures. The 1996 edition of AASHTO Standard Specification for Highway Bridges stated that nominal reinforcement be placed to enclose the prestressing steel from the end of the girder for at least a distance equal to the girder’s height. A few years later the 2004 AASHTO LRFD Bridge Design Specification changed the distance over which the confinement was to be distributed from 1.0h to 1.5h, and gave minimum requirements for the amount of steel to be used, No.3 bars, and their maximum spacing, not to exceed 6”. Research was undertaken to study what impact, if any, confinement reinforcement has on the performance of prestressed concrete bridge girders. Of particular interest was the effect confinement had on the transfer length, development length, and vertical shear capacity of the fore mentioned members. First, an analytical investigation was performed on the subject, and then an experimental investigation followed which consisted of designing, fabricating, and testing eight tee-girders and three NU1100 girders with particular attention paid to the amount and distribution of confinement reinforcement placed at the end of each girder. The results of the study show: 1) neither the amount or distribution of confinement reinforcement had a significant effect on the initial or final transfer length of the prestress strands; 2) at the AASHTO calculated development length, no significant impact from confinement was found on either the nominal flexural capacity of bridge girders or bond capacity of the prestressing steel; 3) the effects from varied confinement reinforcement on the shear resistance of girders tested was negligible, however, distribution of confinement did show to have an impact on the prestressed strands’ bond capacity; 4) confinement distribution across the entire girder did increase ductility and reduced cracking under extreme loading conditions.

Approccio agli spostamenti per la valutazione della vulnerabilità sismica di telai in conglomerato cementizio armato.

Il presente lavoro ha lo scopo di presentare gli studi e i risultati ottenuti durante l’attività di ricerca svolta sul Displacement-based Assessment (DBA) dei telai in cemento armato. Dopo alcune considerazioni iniziali sul tema della vulnerabilità sismica e sui metodi di analisi e verifica, si procede alla descrizione teorica del metodo. Sono stati analizzati tre casi studio di telai piani, progettati per soli carichi verticali e secondo normative non più in vigore che non prevedevano l’applicazione della gerarchia delle resistenze. I telai considerati, destinati ad abitazione civile, hanno diversa altezza e numero di piani, e diverso numero di campate. Si è proceduto all’applicazione del metodo, alla valutazione della vulnerabilità sismica in base alla domanda in termini di spostamento costituita da uno spettro elastico previsto dall’EC8 e alla validazione dei risultati ottenuti mediante analisi non lineari statiche e dinamiche e mediante l’applicazione dei teoremi dell’Analisi limite dei telai, proposta come procedura alternativa per la determinazione del meccanismo anelastico e della capacità in termini di taglio alla base. In ultimo si è applicata la procedura DBA per la valutazione della vulnerabilità sismica di un edificio scolastico, realizzato tra il 1969 e il 1975 in un sito caratterizzato da una accelerazione di picco orizzontale pari a 0,24g e una probabilità di superamento del 10% in 75 anni.

Análisis de los modelos de comportamiento de vigas de hormigón armado reforzadas a cortante con polímeros armados con fibras (frp). Validación y calibración experimental

Los polímeros armados con fibras (FRP) se utilizan en refuerzos de estructuras de hormigón debido sobre todo a sus excelentes propiedades mecánicas, su resistencia a la corrosión y a su ligereza que se traduce en facilidad y ahorro en el transporte, puesta en obra y aplicación, la cual se realiza de forma muy rápida, con pocos operarios y utilizando medios auxiliares ligeros, minimizándose las interrupciones del uso de la estructura y las molestias a los usuarios. Las razones presentadas anteriormente, han despertado un gran inter´es por parte de diferentes grupos de investigación a nivel mundial y que actualmente se encuentran desarrollando nuevas técnicas de aplicación y métodos de cálculo. Sin embargo, las investigaciones realizadas hasta la fecha, muestran un procedimiento bien definido y aceptado en lo referente al cálculo a flexión, lo cual no ocurre con el refuerzo a cortante y aunque se ha demostrado que el refuerzo con FRP es un sistema eficaz para incrementar la capacidad ´ultima frente a esfuerzos cortantes, también se pone de manifiesto la necesidad de más estudios experimentales y teóricos para avanzar en el entendimiento de los mecanismos involucrados para este tipo de refuerzo y establecer un procedimiento de diseño apropiado que maximice las excelentes propiedades de este material. Los modelos que explican el comportamiento del refuerzo a cortante de elementos de hormigón armado son complejos y sin transposición directa a fórmulas ingenieriles. Las normas actualmente en vigor, generalmente, establecen empíricamente la capacidad cortante como la suma de las capacidades del hormigón y el refuerzo transversal de acero. Cuando un elemento es reforzado externamente con FRP, los modelos son evidentemente aun más complejos. Las guías y recomendaciones existentes proponen calcular la capacidad del elemento añadiendo la resistencia aportada por el refuerzo externo de FRP a la ya dada por el hormigón y acero transversal. Sin embargo, la idoneidad de este acercamiento es cuestionable puesto que no tiene en cuenta una posible interacción entre refuerzos. Con base en lo anterior se da origen al tema objeto de este trabajo, el cual está orientado al estudio a cortante de elementos de hormigón armado (HA), reforzados externamente con material compuesto de tejido unidireccional de fibra de carbono y resina epoxi. Inicialmente se hace una completa revisión del estado actual del conocimiento de la resistencia a cortante en elementos de hormigón armado con y sin refuerzo externo de FRP, prestando especial atención en los mecanismos actuantes estudiados hasta la fecha. La bibliografía consultada ha sido exhaustiva y actualizada lo que ha permitido el estudio de los modelos propuestos más importantes, tanto para la descripción del fenómeno de adherencia entre hormigón-FRP como de la valoración del aporte al cortante total hecho por el FRP, a través de sendas bases de datos de ensayos de pull-out y de vigas de hormigón armado ensayadas a cortante. Con base en todo lo anterior, se expusieron los mecanismos actuantes en el aporte a cortante hecho por el FRP en elementos de hormigón armado y la forma como las principales guías de cálculo existentes hasta la fecha los abordan. De igual forma se define un modelo de resistencia de esfuerzos para el FRP y se proponen dos modelos para el cálculo de las tensiones o deformaciones efectivas, de los cuales uno esta basado en el modelo de adherencia propuesto por Oller (2005) y el otro en una regresión multivariante para los mecanismos expuestos. Como complemento del estudio de los trabajos encontrados en la literatura, se lleva acabo un programa experimental que, además de aportar más registros a la exigua base de datos existentes, aporte mayor luz a los puntos que se consideran están deficientemente resueltos. Dentro de este programa se realizaron 32 ensayos sobre 16 vigas de 4.5 m de longitud (dos ensayos por viga), reforzadas a cortante con tejido unidireccional de CFRP. Finalmente, estos estudios han permitido proponer modificaciones a las formulaciones existentes en los códigos y guías en vigor. Abstract Its excellent mechanical properties, as well as its corrosion resistance and light weight, which make it easy to apply and inexpensive to ship to the worksite, are the basis of the extended use of fiber reinforced polymer (FRP) as external strengthening for structures. FRP strengthening is a rapid operation calling for only limited labor and lightweight ancillary equipment, all of which minimizes both the interruption of facility usage and user inconvenience. These advantages have aroused considerable interest in civil engineering science and technology and have led to countless applications the world over. Research studies on the shear strength of FRP-strengthened members have been much fewer in number and more controversial than the research on flexural strengthening, for which a more or less standardized and generally accepted procedure has been established. The research conducted and a host of applications around the world have shown that FRP strengthening is an effective technique for raising ultimate shear strength, but it has also revealed a need for further experimental and theoretical research to advance in the understanding of the mechanisms involved and establish suitable design procedures that optimize the excellent properties of this material The models that explain reinforced concrete (RC) shear strength behavior are complex and cannot be directly transposed to engineering formulas. The standards presently in place generally establish shear capacity empirically as the sum of the capacities of the concrete and the passive reinforcement. When members are externally strengthened with FRP, the models are obviously even more complex. The existing guides and recommendations propose calculating capacity by adding the external strength provided by the FRP to the contributions of the concrete and passive reinforcement. The suitability of this approach is questionable, however, because it fails to consider the interaction between passive reinforcement and external strengthening. The subject of this work is based in above, which is focused on externally shear strengthening for reinforced concrete members with unidirectional carbon fiber sheets bonded with epoxy resin. v Initially a thorough literature review on shear of reinforced concrete beams with and without external FRP strengthening was performed, paying special attention to the acting mechanisms studied to date, which allowed the study of the most important models both to describe the bond phenomenon as well as calculating the FRP shear contribution, through separate databases of pull-out tests and shear tests on reinforced concrete beams externally strengthened with FRP. Based on above, they were exposed the acting mechanisms in a FRP shear strengthening on reinforced concrete beams and how guidelines deal the topic. The same way, it is defined a FRP stress strength model and two more models are proposed for calculating the effective stress, one of these is based on the Oller (2005) bond model and another one is the data best fit, taking into account most of the acting mechanisms. To complement the theoretical part we develop an experimental program that, in addition to providing more records to the meager existing database provide greater understanding to the points considered poorly resolved. The test program included 32 tests of 16 beams (2 per beam) of 4.5 m long, shear strengthened with FRP, externally. Finally, modifications to the existing codes and guidelines are proposed.

Estimación de la resistencia de estructuras de hormigón armado reforzadas a cortante mediante FRP

El empleo de refuerzos de FRP en vigas de hormigón armado es cada vez más frecuente por sus numerosas ventajas frente a otros métodos más tradicionales. Durante los últimos años, la técnica FRP-NSM, consistente en introducir barras de FRP sobre el recubrimiento de una viga de hormigón, se ha posicionado como uno de los mejores métodos de refuerzo y rehabilitación de estructuras de hormigón armado, tanto por su facilidad de montaje y mantenimiento, como por su rendimiento para aumentar la capacidad resistente de dichas estructuras. Si bien el refuerzo a flexión ha sido ampliamente desarrollado y estudiado hasta la fecha, no sucede lo mismo con el refuerzo a cortante, debido principalmente a su gran complejidad. Sin embargo, se debería dedicar más estudio a este tipo de refuerzo si se pretenden conservar los criterios de diseño en estructuras de hormigón armado, los cuales están basados en evitar el fallo a cortante por sus consecuencias catastróficas Esta ausencia de información y de normativa es la que justifica esta tesis doctoral. En este pro-yecto se van a desarrollar dos metodologías alternativas, que permiten estimar la capacidad resistente de vigas de hormigón armado, reforzadas a cortante mediante la técnica FRP-NSM. El primer método aplicado consiste en la implementación de una red neuronal artificial capaz de predecir adecuadamente la resistencia a cortante de vigas reforzadas con este método a partir de experimentos anteriores. Asimismo, a partir de la red se han llevado a cabo algunos estudios a fin de comprender mejor la influencia real de algunos parámetros de la viga y del refuerzo sobre la resistencia a cortante con el propósito de lograr diseños más seguros de este tipo de refuerzo. Una configuración óptima de la red requiere discriminar adecuadamente de entre los numerosos parámetros (geométricos y de material) que pueden influir en el compor-tamiento resistente de la viga, para lo cual se han llevado a cabo diversos estudios y pruebas. Mediante el segundo método, se desarrolla una ecuación de proyecto que permite, de forma sencilla, estimar la capacidad de vigas reforzadas a cortante con FRP-NSM, la cual podría ser propuesta para las principales guías de diseño. Para alcanzar este objetivo, se plantea un pro-blema de optimización multiobjetivo a partir de resultados de ensayos experimentales llevados a cabo sobre vigas de hormigón armado con y sin refuerzo de FRP. El problema multiobjetivo se resuelve mediante algoritmos genéticos, en concreto el algoritmo NSGA-II, por ser más apropiado para problemas con varias funciones objetivo que los métodos de optimización clásicos. Mediante una comparativa de las predicciones realizadas con ambos métodos y de los resulta-dos de ensayos experimentales se podrán establecer las ventajas e inconvenientes derivadas de la aplicación de cada una de las dos metodologías. Asimismo, se llevará a cabo un análisis paramétrico con ambos enfoques a fin de intentar determinar la sensibilidad de aquellos pa-rámetros más sensibles a este tipo de refuerzo. Finalmente, se realizará un análisis estadístico de la fiabilidad de las ecuaciones de diseño deri-vadas de la optimización multiobjetivo. Con dicho análisis se puede estimar la capacidad resis-tente de una viga reforzada a cortante con FRP-NSM dentro de un margen de seguridad espe-cificado a priori. ABSTRACT The use of externally bonded (EB) fibre-reinforced polymer (FRP) composites has gained acceptance during the last two decades in the construction engineering community, particularly in the rehabilitation of reinforced concrete (RC) structures. Currently, to increase the shear resistance of RC beams, FRP sheets are externally bonded (EB-FRP) and applied on the external side surface of the beams to be strengthened with different configurations. Of more recent application, the near-surface mounted FRP bar (NSM-FRP) method is another technique successfully used to increase the shear resistance of RC beams. In the NSM method, FRP rods are embedded into grooves intentionally prepared in the concrete cover of the side faces of RC beams. While flexural strengthening has been widely developed and studied so far, the same doesn´t occur to shearing strength mainly due to its great complexity. Nevertheless, if design criteria are to be preserved more research should be done to this sort of strength, which are based on avoiding shear failure and its catastrophic consequences. However, in spite of this, accurately calculating the shear capacity of FRP shear strengthened RC beams remains a complex challenge that has not yet been fully resolved due to the numerous variables involved in the procedure. The objective of this Thesis is to develop methodologies to evaluate the capacity of FRP shear strengthened RC beams by dealing with the problem from a different point of view to the numerical modeling approach by using artificial intelligence techniques. With this purpose two different approaches have been developed: one concerned with the use of artificial neural networks and the other based on the implementation of an optimization approach developed jointly with the use of artificial neural networks (ANNs) and solved with genetic algorithms (GAs). With these approaches some of the difficulties concerned regarding the numerical modeling can be overcome. As an alternative tool to conventional numerical techniques, neural networks do not provide closed form solutions for modeling problems but do, however, offer a complex and accurate solution based on a representative set of historical examples of the relationship. Furthermore, they can adapt solutions over time to include new data. On the other hand, as a second proposal, an optimization approach has also been developed to implement simple yet accurate shear design equations for this kind of strengthening. This approach is developed in a multi-objective framework by considering experimental results of RC beams with and without NSM-FRP. Furthermore, the results obtained with the previous scheme based on ANNs are also used as a filter to choose the parameters to include in the design equations. Genetic algorithms are used to solve the optimization problem since they are especially suitable for solving multi-objective problems when compared to standard optimization methods. The key features of the two proposed procedures are outlined and their performance in predicting the capacity of NSM-FRP shear strengthened RC beams is evaluated by comparison with results from experimental tests and with predictions obtained using a simplified numerical model. A sensitivity study of the predictions of both models for the input parameters is also carried out.

Numerical prediction of the lateral displacement capacity of flexural reinforced concrete shear walls

Previous earthquakes showed that shear wall damage could lead to catastrophic failures of the reinforced concrete building. The lateral load capacity of shear walls needs to be estimated to minimize associated losses during catastrophic events; hence it is necessary to develop and validate reliable and stable numerical methods able to converge to reasonable estimations with minimum computational effort. The beam-column 1-D line element with fiber-type cross-section model is a practical option that yields results in agreement with experimental data. However, shortcomings of using this model to predict the local damage response may come from the fact that the model requires fine calibration of material properties to overcome regularization and size effects. To reduce the mesh-dependency of the numerical model, a regularization method based on the concept of post-yield energy is applied in this work to both the concrete and the steel material constitutive laws to predict the nonlinear cyclic response and failure mechanism of concrete shear walls. Different categories of wall specimens known to produce a different response under in plane cyclic loading for their varied geometric and detailing characteristics are considered in this study, namely: 1) scaled wall specimens designed according to the European seismic design code and 2) unique full-scale wall specimens detailed according to the U.S. design code to develop a ductile behavior under cyclic loading. To test the boundaries of application of the proposed method, two full-scale walls with a mixed shear-flexure response and different values of applied axial load are also considered. The results of this study show that the use of regularized constitutive models considerably enhances the response predictions capabilities of the model with regards to global force-drift response and failure mode. The simulations presented in this thesis demonstrate the proposed model to be a valuable tool for researchers and engineers.

Bending fatigue of stainless steel shear pins belonging to a hydroelectric plant

Coaracy Nunes was the first hydroelectric power plant in the Amazon region, being located in Araguari River, Amapa State, Brazil. The plant operates since 1976, presenting now a nominal capacity of 78 MW. The shear pins, which are installed in the turbine hydraulic arms to control the wicket gate and regulate the water flow into the turbine blades, suffered several breakdowns since 2004. These shear pins are made of an ASTM 410 stainless steel and were designed to break by a shear overload of 120 kN. Fractographic investigation of the pins, however, revealed two types of fracture topographies: a region of stable crack propagation area, with non-pronounced striation and secondary cracks; and a region of unstable propagation, featuring elongated dimples. These results indicated that the stable crack propagation occurred by fatigue (bidirectional bending), which was nucleated at machining marks under high nominal load. Finite element analysis was carried out using two loading conditions (pure shear and a combination of shear and bending) and the results indicated that the presence of a bending stress strongly increased the stress concentration factor (85% rise in the shear stress and 130% rise in the Von Mises stress). Misalignment during shear pins assembly associated with vibration might have promoted the premature failure of the shear by bending fatigue. (C) 2008 Elsevier Ltd. All rights reserved.