Grain size based low cycle fatigue life prediction model for nickel-based superalloy

Nickel-based superalloys are easy to produce low cycle fatigue(LCF)damage when they are subjected to high temperature and mechanical stresses.Fatigue life prediction of nickel-based superalloys is of great importance for their reliable practical application.To investigate the effects of total strain and grain size on LCF behavior,the high temperature LCF tests were carried out for a nickel-based superalloy.The results show that the fatigue lives decreased with the increase of strain amplitude and grain size.A new LCF life prediction model was established considering the effect of grain size on fatigue life.Error analyses indicate that the prediction accuracy of the new LCF life model is higher than those of Manson-Coffin relationship and Ostergren energy method.

Bi-variable damage model for fatigue life prediction of metal components

Based on the theory of continuum damage mechanics,a bi-variable damage mechanics model is developed,which,according to thermodynamics,is accessible to derivation of damage driving force,damage evolution equation and damage evolution criteria. Furthermore,damage evolution equations of time rate are established by the generalized Drucker＇s postulate. The damage evolution equation of cycle rate is obtained by integrating the time damage evolution equations,and the fatigue life prediction method for smooth specimens under repeated loading with constant strain amplitude is constructed. Likewise,for notched specimens under the repeated loading with constant strain amplitude,the fatigue life prediction method is obtained on the ground of the theory of conservative integral in damage mechanics. Thus,the material parameters in the damage evolution equation can be obtained by reference to the fatigue test results of standard specimens with stress concentration factor equal to 1,2 and 3.

Residual Fatigue Life Prediction of Ball Bearings Based on Paris Law and RMS

Paris law can reflect the failure mechanism of materials and is usually used to be a method to predict fatigue life or residual fatigue life.But the variable which can represent the health of machine is hardly measured on line.To a degree,the difficulty of on-line application restricts the scope of application of Paris law.The relationship between characteristic values of vibration signals and the variable in the Paris equation which can describe the health of machine is investigated by taking ball bearings as investigative objects.Based on 6205 deep groove ball bearings as a living example,historical lives and vibration signals are analyzed.The feasibility of describing that variable in the Paris equation by the characteristic value of vibration signals is inspected.After that vibration signals decomposed by empirical mode decomposition（EMD）,root mean square（RMS） of intrinsic mode function（IMF） involving fault characteristic frequency has a consistent trend with the diameter of flaws.Based on the trend,two improved Paris models are proposed and the scope of application of them is inspected.These two Paris Models are validated by fatigue residual life data from tests of rolling element bearings and vibration signals monitored in the process of operation of rolling element bearings.It shows that the first improved Paris Model is simple and plain and it can be easily applied in actual conditions.The trend of the fatigue residual life predicted by the second improved Paris model is close to the actual conditions and the result of the prediction is slightly greater than the truth.In conclusion,after the appearance of detectable faults,these improved models based on RMS can predict residual fatigue life on line and a new approach to predict residual fatigue life of ball bearings on line without disturbing the machine running is provided.

Fatigue Life Prediction of Rolling Bearings Based on Modified SWT Mean Stress Correction

The existing engineering empirical life analysis models are not capable of considering the constitutive behavior of materials under contact loads;as a consequence,these methods may not be accurate to predict fatigue lives of roll-ing bearings.In addition,the contact stress of bearing in operation is cyclically pulsating,it also means that the bear-ing undergo non-symmetrical fatigue loadings.Since the mean stress has great effects on fatigue life,in this work,a novel fatigue life prediction model based on the modified SWT mean stress correction is proposed as a basis of which to estimate the fatigue life of rolling bearings,in which,takes sensitivity of materials and mean stress into account.A compensation factor is introduced to overcome the inaccurate predictions resulted from the Smith,Watson,and Topper(SWT)model that considers the mean stress effect and sensitivity while assuming the sensitivity coefficient of all materials to be 0.5.Moreover,the validation of the model is finalized by several practical experimental data and the comparison to the conventional SWT model.The results show the better performance of the proposed model,especially in the accuracy than the existing SWT model.This research will shed light on a new direction for predicting the fatigue life of rolling bearings.

A new model for life prediction of GH4133 under TMF conditions

Thermal mechanical cyclic strain tests were carried out under in-phase andout-of-phase conditions on a Nickel-base Superalloy GH4133 in the temperature range of 571-823 degC. Based on analyzing the present models of TMF (thermal mechanical fatigue) life prediction, a newmodel for predicting nickel-base superalloy TMF lifetime was proposed. TMF life of superalloy GH4133was calculated accurately based on the new model. Experimental TMF life has been compared with thecalculated results and all results fall in the scatter band of 1.5. The calculating results showthat the new model is not only simple, but also precise. This model will play great roles as lifeprediction of the metal materials and the engineering components subjected to non-isothermal serviceconditions.

Life Prediction Model for a Nickel-base Single Crystal Superalloy DD3

The possibility of a life prediction model for nickel base single crystal blades has been studied. The fatigue creep (FC) and thermal fatigue creep(TMFC) as well as creep experiments have been carried out with different hold time of DD3. The hold time and the frequency as well as the temperature range are the main factors influencing the life. An emphasis has been put on the micro mechanism of the rupture of creep, FC and TMFC. Two main factors are the voiding and degeneration of the material for the cre...

QUICK ASSESSMENT METHODOLOGY FOR RELIABILITY OF SOLDER JOINTS IN BALL GRID ARRAY (BGA) ASSEMBLY——PART Ⅰ: CREEP CONSTITUTIVE RELATION AND FATIGUE MODEL

In this study, a new unified creep constitutive relation and a mod- ified energy-based fatigue model have been established respectively to describe the creep flow and predict the fatigue life of Sn-Pb solders. It is found that the relation successfully elucidates the creep mechanism related to current constitutive relations. The model can be used to describe the temperature and frequency dependent low cycle fatigue behavior of the solder. The relation and the model are further employed in part Ⅱ to develop the numerical simulation approach for the long-term reliability assessment of the plastic ball grid array (BGA) assembly.

Numerical Simulation of Fretting Fatigue Damage Evolution of Cable Wires Considering Corrosion and Wear Effects

In this paper,a numerical model of fretting fatigue analysis of cablewire and the fretting fatigue damage constitutive model considering the multi-axis effect were established,and the user material subroutine UMAT was written.Then,the constitutive model of wear morphology evolution of cable wire and the constitutive model of pitting evolution considering the mechanical-electrochemical effect were established,respectively.The corresponding subroutines UMESHMOTION_Wear and UMESHMOTION_Wear_Corrosion were written,and the fretting fatigue lifewas further predicted.The results showthat the numerical simulation life obtained by the programin this paper has the same trend as the tested one;the error is only about 0.7%in the medium life area;When the normal contact force increases from 120 to 240 N,the fretting life of cable wire decreases by 25%;When the evolution of wear morphology and corrosion effect are considered simultaneously,the depth of the wear zone exceeds 0.08mm after 600,000 loads,which ismuch larger than 0.04 mmwhen only the evolution of wear morphology is considered.When the evolution of wear morphology and corrosion morphology is considered simultaneously,the damage covers the whole contact surface after 300,000 loads,and the penetrating damage zone forms after 450,000 loads,which is obviously faster than that when only the wearmorphology evolution is considered.Themethod proposed in this paper can provide a feasible numerical simulation scheme for the visualization of the damage process and accurate life prediction of cable-supported bridges.

低周载荷下NiTi微动疲劳寿命预测模型研究

微动磨损加速材料疲劳失效,微动疲劳是微动磨损和普通疲劳共同作用的结果;NiTi形状记忆合金具有良好的耐磨性和抗疲劳特性,可以延缓损伤的发生和扩展;改进原有的微动疲劳寿命预测模型,将微动磨损作为影响微动疲劳寿命的重要因素,引入NiTi微动疲劳寿命预测模型中;给出合理有效的NiTi微动疲劳寿命预测模型。

Review on fatigue life prediction models of welded joint

Fatigue assessment of welded joint is still far from being completely solved now,since many influencing factors coexist and some important ones should be considered in the developed life prediction models reasonably.Thus,such influencing factors of welded joint fatigue are firstly summarized in this work;and then,the existing life prediction models are reviewed from two aspects,i.e.,uniaxial and multiaxial ones;finally,significant conclusions of existing experimental and theoretical researches and some suggestions on improving the fatigue assessment of welded joints,especially for the low-cycle fatigue with the occurrence of ratchetting,are provided.

Fatigue life prediction model of 2.5D woven composites at various temperatures

As one of the new structural layout in the family of woven composites, 2.5D Woven Composites（2.5D-WC） have recently attracted an increasing interest owing to its excellent properties, i.e. high specific strength and fatigue resistance, in the aerospace and automobile industry. Indepth understanding of the fatigue behavior of this material at un-ambient temperatures is critical for the engineering applications, especially in aero-engine field. Here, fatigue behavior of 2.5D-WC at different temperatures was numerically investigated based on the unit cell approach. Firstly, the unit cell model of 2.5D-WC was established using ANSYS software. Subsequently, the temperature-dependent fatigue life prediction model was built up. Finally, the fatigue lives alongside the damage evolution processes of 2.5D-WC at ambient temperature（20 ℃） and unambient temperature（180 ℃） were analyzed. The results show that numerical results are in good agreement with the relevant experimental results at 20 and 180 ℃. Fatigue behavior of 2.5D-WC is also sensitive to temperature, which is partially attributed to the mechanical properties of resin and the change of inclination angle of warp yarns. We hope that the proposed fatigue life prediction model and the findings could further promote the engineering application of 2.5D-WC, especially in aero-engine field.

Tension-Torsion High-Cycle Fatigue Life Prediction of 2A12-T4 Aluminium Alloy by Considering the Anisotropic Damage:Model, Parameter Identification, and Numerical Implementation

To consider the anisotropic damage in fatigue, an improved boom-panel model is presented to simulate a representative volume element (RVE) in the framework of continuum damage mechanics. The anisotropic damage state of the RVE is described by the continuity extents of booms and panels, whose damage evolutions are assumed to be isotropic. The numerical implementation is proposed on the basis of damage mechanics and the finite element method. Finally, the approach is applied to the fatigue life prediction of 2A12-T4 aluminium alloy specimen under cyclic loading of tension-torsion. The results indicate a good agreement with the experimental data.

Microstructural characteristics and low-cycle fatigue properties of AZ91 and AZ91-Ca-Y alloys extruded at different temperatures

The commercial AZ91 alloy and nonflammable SEN9(AZ91-0.3Ca-0.2Y,wt%)alloy are extruded at 300°C and 400°C.Their microstructure,tensile and compressive properties,and low-cycle fatigue(LCF)properties are investigated,with particular focus on the influence of the extrusion temperature.In the AZ91 and SEN9 materials extruded at 300°C(300-materials),numerous fine Mg_(17)Al_(12)particles are inhomogeneously distributed owing to localized dynamic precipitation during extrusion,unlike those extruded at 400°C(400-materials).These fine particles suppress the coarsening of recrystallized grains,decreasing the average grain size of 300-materials.Although the four extruded materials have considerably different microstructures,the difference in their tensile yield strengths is insignificant because strong grain-boundary hardening and precipitation hardening effects in 300-materials are offset almost completely by a strong texture hardening effect in 400-materials.However,owing to their finer grains and weaker texture,300-materials have higher compressive yield strengths than400-materials.During the LCF tests,{10-12}twinning is activated at lower stresses in 400-materials than in 300-materials.Because the fatigue damage accumulated per cycle is smaller in 400-materials,they have longer fatigue lives than those of 300-materials.A fatigue life prediction model for the investigated materials is established on the basis of the relationship between the total strain energy density(ΔW_(t))and the number of cycles to fatigue failure(N_(f)),and it is expressed through a simple equation(ΔW_(t)=10·N_(f)-0.59).This model enables fatigue life prediction of both the investigated alloys regardless of the extrusion temperature and strain amplitude.

Low cycle fatigue behavior of zirconium−titanium−steel composite plate

The low cycle fatigue behavior of zirconium−titanium−steel composite plate under symmetrical and asymmetric stress control was studied.The effects of mean stress and stress amplitude on cyclic deformation,ratcheting effect and damage mechanism were discussed in detail.The results show that under symmetric stress control,the forward ratcheting deformation is observed.Under asymmetric stress control,the ratcheting strain increases rapidly with mean stress and stress amplitude increasing.Under high stress amplitude,the influence of mean stress is more significant.In addition,by studying the variation of strain energy density,it is found that the stress amplitude mainly promotes the fatigue damage,while the mean stress leads to the ratcheting damage.In addition,fractographic observation shows that the crack initiates in the brittle metal compound at the interface,and the steel has higher resistance to crack propagation.Finally,the accuracy of life prediction model considering ratcheting effect is discussed in detail,and a high-precision life prediction model directly based on mean stress and stress amplitude is proposed.

Fatigue Life Prediction for NiTi Shape Memory Alloy Micro-tubes Under Uniaxial Stress-Controlled One-Way Shape Memory Cyclic Loading

By choosing the dissipation energy as the damage variable,corresponding damage evolution equations are established,respectively,for the mechanical cyclic loading part and the thermal one during the thermo-mechanical cyclic loading of NiTi shape memory alloys(SMAs)involving one-way shape memory effect(simply denoted as the OWSME cycling).And then,the evolution law of total damage is obtained by a superposition of such two damage parts.Finally,the uniaxial OWSME fatigue lives of NiTi SMA micro-tubes are predicted by combining the proposed damage model with an adopted failure criterion.The results show that all the predicted fatigue lives are located within the twice scatter band with regard to the experimental ones,and most of them are located within a scatter band of 1.5 times.It is indicated that the predicted OWSME fatigue lives are in good agreement with the experimental ones.

Effect of Loading Frequency on the High Cycle Fatigue Strength of Flax Fiber Reinforced Polymer Matrix Composites

Among natural fibers,flax fiber reinforced polymer matrix composites show excellent dynamic/fatigue properties due to its excellent damping properties.Knowledge about fatigue limit and effect of loading frequency on fatigue limit is very crucial to know before being used a member as a structural component.Fatigue limit of fiber reinforced composite is measured through high cycle fatigue strength(HCFS).The effect of loading frequency on the HCFS of flax fiber reinforced polymer matrix composites was investigated using stabilized specimen surface temperature based thermographic and dissipated energy per cycle-based approaches.Specimens of unidirectional flax fiber reinforced thermoset composites were tested under cyclic loading at different percentages of applied stresses for the loading frequencies of 5,7,10,and 15 Hz in order to determine the stabilized surface temperature of the specimen and dissipated energy per fatigue cycle.Both approaches predicted similar fatigue limits(HCFS)which showed a good agreement with experimental results from Literature.HCFS of flax fiber reinforced composites decrease little with increasing loading frequency.Furthermore,effect of loading frequency on stabilized specimen temperature and dissipated energy per fatigue cycle was also investigated.Although specimen surface temperature increases with loading frequency,dissipated energy per-cycle does not change with loading frequency.Thermal degradation at higher loading frequencies may play a significant role in decreasing HCFS with increasing loading frequency.

非对称循环载荷下铝基复合材料的疲劳寿命预测

铝基复合材料由不同力学性能和疲劳行为的多种材料组成。在非对称循环载荷下,各组分间的相互作用和影响使其疲劳寿命预测变得复杂。为解决这一问题,研究一种非对称循环载荷下铝基复合材料疲劳寿命预测方法。用Na_(3)Al F_(6)和Ti O_(2)粉末强化铝合金基体,制备出复合材料样品。设计非对称循环载荷加载条件。用Walker裂纹扩展式结合Chaboche模型进行铝基复合材料疲劳寿命预测,Chaboche模型能较好地描述材料在循环加载下的非线性行为;通过引入应力比参数,Walker公式可更准确地预测裂纹在不同应力水平下的扩展行为。将两者结合能更全面地考虑材料在疲劳过程中的各种因素,从而提高疲劳寿命预测的准确性。结果表明:随着应力幅值的增加,试件裂缝长度随之上升,同时随着循环圈数的增加,试件应力随之上升,这使得铝基复合材料疲劳寿命下降,且该方法的预测结果与实测值更接近,说明预测结果可靠。

冻融作用下高速铁路路基沥青混凝土防水封闭结构疲劳寿命预测模型

以高速铁路路基沥青混凝土防水封闭结构为研究对象,考虑季节性冻土地区的气象条件设计了疲劳试验和冻融循环试验,研究冻融循环作用对其疲劳特性参数演变规律的影响。结合平稳值与冻融循环周期的作用规律,提出了高速铁路路基沥青混凝土防水封闭结构在冻融循环作用下的疲劳寿命预测模型,并利用疲劳极限临界点的平均值对此疲劳寿命预测模型进行了可靠性验证。结果表明:沥青混凝土耗散能变化率与加载次数曲线在冻融前后呈现三个阶段;沥青混凝土防水封闭结构的疲劳寿命随冻融循环次数的增多而降低,且降低幅度越来越大,其抗疲劳性能受到显著损伤;经验证,高速铁路路基沥青混凝土防水封闭结构疲劳寿命预测模型准确、可靠。

P型橡胶卡箍的拉压疲劳性能测试和寿命预测

P型橡胶卡箍是航空发动机外部管路系统中连接管路与支架、机匣之间的重要连接件,其主要的失效形式为机体振动和管内高压液体脉动共同作用下的疲劳断裂。卡箍的疲劳性能极大地制约了管路系统的性能,因此对于卡箍的疲劳性能研究具有重要意义。本文首先设计并进行了卡箍的拉压疲劳试验,得到了不同加载位移下的疲劳寿命。后续的断口分析表明卡箍疲劳破坏呈现出两种不同的形式:一是卡箍的金属箍带发生由外侧向内侧扩展的疲劳断裂,二是卡箍的橡胶垫圈严重的磨损现象。其次,结合卡箍疲劳试验的加载过程,建立了对应的有限元模型,并通过与贴片位置的应变对比验证了构建模型的预测精度。针对卡箍箍带疲劳断裂的失效形式,通过卡箍箍带所采用的不锈钢材料的疲劳试验结果,建立了卡箍的SWT(Smith-Watson-Topper)、FS(Fatemi-Socie)以及WB(Wang-Brown)临界平面疲劳寿命模型。最后,结合有限元分析得到的最大应力应变以及卡箍拉压疲劳试验得到的疲劳寿命结果,验证了提出的寿命模型均处于3倍分散带内,对于卡箍的疲劳寿命具有良好的估计精度。

碳纤维增强复合材料疲劳寿命分析

为实现碳纤维增强复合材料疲劳寿命的便捷、高精度评估,开展了两种碳纤维增强树脂基复合材料在不同应力比下的疲劳试验研究,分析了不同应力比下的疲劳破坏过程和失效模式,提出了一种考虑应力水平和应力比的碳纤维增强复合材料疲劳寿命评估模型。通过两种材料的拉-压和压-压疲劳试验,验证了该模型的适用性。本文所建立的疲劳寿命评估模型预估寿命与试验寿命偏差小于2.5倍分散带。