Thermal-Mechanical Fatigue Behavior and Life Analysis of Cast Ni-base Superalloy K417

In-phase (IP) and out-of-phase (OP) thermal-mechanical fatigue (TMF) behavior of cast Ni-base superalloy K417 was studied. All experiments were carried out under total strain control with temperature cycling between 400-850℃. Both in-phase and out-of-phase TMF specimens exhibited cyclic hardening followed by cyclic softening at the minimum temperature. Besides, they cyclically hardened in the early stage of life followed by cyclic softening at the maximum temperature. OP TMF life was longer than that of IP TMF. Various damage mechanisms operating in different controlled strain ranges and phasing were discussed. A few life prediction methods for isothermal fatigue were used to handle TMF fatigue and their applicability to superalloy K417 was evaluated. The SEM analysis of the fracture surface showed that transgranular fracture was the principal cracking mode for both IP and OP TMF. Oxidation was the main damage mechanism in causing shorter fatigue life for IP TMF compared with OP TMF.

Novel aspects for thermal stability studies and shelf life assessment of modified double-base propellants

Modified DB propellants, based on energetic nitramine(RDX) were manufactured by solventless extrusion process. Thermal stability and shelf life assessment of modified DB propellant were investigated. Shelf life assessment was evaluated using Van’t Hoff’s formula and artificial aging at 70℃ up to120 days. Quantification of total heat released and heat flow with aging time was conducted using differential scanning calorimetry(DSC) and thermal activity monitoring(TAMIII) respectively. Modified DB formulation based on 20 wt % RDX demonstrated enhanced thermal stability in terms of controlled heat flow, and slow decomposition reactions at elevated temperature. This formulation demonstrated extended service life up to 56 years compared with reference formulation. These novel finding was ascribed to the high thermal stability of RDX and its compatibility with DB constituents. This manuscript shaded the light on novel and effective approach for thermal stability via monitoring thermal activity with aging.

Chemical stability, thermal behavior, and shelf life assessment of extruded modified double-base propellants

Double base propellant suffers from lack of chemical stability; this could result in self ignition during storing. Modified double base(MDB) propellant based on stoichiometric binary mixture of oxidizermetal fuel(Ammonium perchlorate/Aluminum), and energetic nitramines(HMX) offered enhanced thrust as well as combustion characteristics. This study is devoted to evaluate the impact of such energetic additives on thermal behavior, chemical stability, and shelf life. Extruded MDB formulations were manufactured by extrusion process. Artificial aging at 80℃ for 28 days was conducted. Shelf life assessment was performed using Van't Hoff's equation. Quantification of evolved NOxgases with aging time was performed using quantitative stability tests. MDB formulation based on HMX demonstrated extended service life of 16 years compared with(AP/Al)-MDB which demonstrated 9 years. This finding was ascribed to the reactivity of AP with nitroglycerin with the formation of perchloric acid. Thermal behavior of aged MDB, exhibited an increase in heat released with time; this was ascribed to the autocatalytic thermal degradation during artificial aging. The increase in released heat by 31% was found to be equivalent to evolved NOx gases of 6.2 cm^3/5 g and 2.5 cm^3/1 g for Bergmann-Junk test, and Vacuum stability test respectively. This manuscript shaded the light on a novel approach to quantify evolved NOx gases to heat released with aging time. MDB based on HMX offered balanced ballistic performance,chemical stability, and service life.

FRACTURE MECHANICS ANALYSIS OF THERMAL STRAINFATIGUE LIFE FOR THE SINTERING MACHINE PALLET

In recent years elastic-plastic fracture mechanics has developed rapidly and is widely used to solve various engineering problems. The application of elastic-plastic fracture mechanics on the pallet of sintering machine is approached in detail for the first time in the present study. The theoretical results were compared with the actual data determined from sintering machine pallet. Results show that good agreement was achieved between the method suggested by the author and the actual data. The basis of determining design of the sintering machine pallet in iron and steel engineering has been provided and it will result in great economic benefits.

Influences of fine pitch solder joint shape parameters on fatigue life under thermal cycle

The solder joint reliability of a 0.5mm lead pitch, 240-pin quad flat package(QFP) was studied by nonlinear finite element analysis(FEA). The stress/strain distributions within the solder joints and the maximum plastic strain range of the solder joints were determined. Based on the calculated maximum plastic strain range the thermal fatigue life of the solder joints was calculated using Coffin-Manson equation. The influences of shape parameters including volume of solder joint, pad size and stand-off on the thermal fatigue life of the solder joints were also studied. The results show that the stress and strain distribution in the solder joint are not uniform; the interface between the lead and the solder joint is the high stress and strain region; the maximum stress and stain occur at the topmost point where the solder joint intersects with the inner side of the lead. The solder joint cracks should occur firstly at this point and propagate along the interface between the solder and the lead. The solder joint with the pad size of 1.25mm×0.35mm, the stand-off of 0.02mm and the solder volume of 0.026mm^3 has longer fatigue life than that of any others. These optimal parameters have been applied in practice to assemble the 240-pin, 0.5mm pitch QFP.

Calculation of Thermal Stress and Fatigue Life of 1000 MW Steam Turbine Rotor

The paper calculated the temperature and stress fields of 1000 MW ultra-supercritical steam turbine rotors which start in cold condition using the finite element calculation program (ANSYS). After getting rotor stress field, the paper use the general slope method to estimate the low cycle fatigue life loss, the rest of the conditions can be calculated in this method.

Influence of Thermal Load on Mechanical Property of Cemented Carbide Material and Heavy Cemented Carbide Inserts Life

A large amount of cutting heat is produced during the heavy cutting process,and insert life is restricted by the effect of thermal load.The thermal load experiment of cemented carbide SCS,WF and YT15 is carried out,and the results show that the bending strength and fracture toughness of cemented carbide material decrease obviously under cyclic thermal load,while in the cooling process,the material mechanical property changes worse suddenly.The high-temperature mechanical property of SCS is the most stable,and that of YT15 is the worst.Further,a relation model among cutting temperature,cutting parameters and insert life is established.Finally,the measures to improve heavy cemented carbide inserts life are summarized from the aspects of cutting parameters selection,insert optimization design and TiCN,Al2O3,TiN complex insert coating.The research results are expected to provide support and reference for heavy cutting technology and insert technology.

Application of time-temperature superposition method in thermal aging life prediction of shipboard cables

The life of shipboard cables will decrease due to the complex aging processes. In terms of the safety perspective, remaining life prediction of the cable is essential to maintain a reliable operation. In this paper, firstly, based on Arrhenius equation, residual life of new styrene-butadiene cable is calculated; result indicates that the degradation rate which changes with time is proportional to thermal temperature. Then second order dynamic model is adopted into the residual life prediction, combined with the time-temperature superposition method(TTSP), and a new residual life model is proposed. According to the accelerated thermal aging experiment data and Arrhenius equation, TTSP method demonstrates to be an efficient way for life prediction, and life at normal temperature can be estimated by this model. In order to monitor the state of styrene-butadiene cable more accurately, an improved residual life model based on equivalent environment temperature of cable is proposed, and life of cable under real operation is analyzed. Result indicates that this model is credible and reliable, and it provides an important theoretical base for residual life of cables.

End-of-life vehicles processing,towards a thermal treatment of auto shredder residue

All over the world,the management of End-of-life Vehicles(ELV) and Automobile Shredder Residue(ASR) is an increasing issue for the car industry.The setting up of several environmental directives,among others the notion of extended producer responsibility,encourage car manufacturers to find alternatives solutions to waste disposal.For 2017,China aims for the recyclability and energy recovery of 95% of total weight of used cars,and in order to reach this rate,the development of some ASR thermal processes could be envisaged.With this research,an overview of ELV management was given and the different solutions about ASR thermal treatment were presented.It is showed that in spite of its big heterogeneity,the high heating value of ASR makes pyrolysis and gasification very interesting,compared to incineration or disposal of in landfills.

A Review of the Life Cycle Analysis for Plastic Waste Pyrolysis

Pyrolysis is a rapidly expanding chemical-based recyclable method that complements physical recycling. It avoids improper disposal of post-consumer polymers and mitigates the ecological problems linked to the production of new plastic. Nevertheless, while there is a consensus that pyrolysis might be a crucial technology in the years to come, more discussions are needed to address the challenges related to scaling up, the long-term sustainability of the process, and additional variables essential to the advancement of the green economy. Herein, it emphasizes knowledge gaps and methodological issues in current Life Cycle Assessment (LCA), underlining the need for standardized techniques and updated data to support robust decision-making for adopting pyrolysis technologies in waste management strategies. For this purpose, this study reviews the LCAs of pyrolytic processes, encompassing the complete life cycle, from feedstock collection to end-product distribution, including elements such as energy consumption, greenhouse gas emissions, and waste creation. Hence, we evaluate diverse pyrolysis processes, including slow, rapid, and catalytic pyrolysis, emphasizing their distinct efficiency and environmental footprints. Furthermore, we evaluate the impact of feedstock composition, process parameters, and scale of operation on the overall sustainability of pyrolysis-based plastic waste treatment by integrating results from current literature and identifying essential research needs. Therefore, this paper argues that existing LCA studies need more coherence and accuracy. It follows a thorough evaluation of previous research and suggests new insights into methodologies and restrictions.

A Study of Estimating the Safe Storage Life, Self-accelerating Decomposition Temperature and Critical Temperature of Thermal Explosion of Double-base Propellant Using Isothermal and Non-isothermal Decomposition Behaviours

A method of estimating the safe storage life （τ）, self-accelerating decomposition temperature （TsADT） and critical temperature of thermal explosion （Tb） of double-base propellant using isothermal and non-isothermal decomposition behaviours is presented. For double-base propellant composed of 56±1wt% of nitrocellulose （NC）, 27±0.5wt% of nitroglycerine （NG）, 8.15±0.15wt% of dinitrotoluene （DNT）, 2.5±0.1wt% of methyl centralite, 5.0±0.15wt% of catalyst and 1.0±0.1wt% of other, the values of r of 49.4 years at 40℃, of TSAOT of 151.35℃ and of Tb of 163.01℃ were obtained.

Effect of Thermal Cycling on Properties and Microstructure of SnAgCuCe Soldered Joints in QFP Devices

Increasing global concern about the environment is bringing regulatory （European directives） and consumer （＂green products＂） pressure on the electronics industry in Europe and Japan to reduce or completely eliminate the use of lead （Pb） in products. Among all lead-free solder alloys, SnAgCu solder system, which has better thermo-mechanical properties compared with those of SnPb solder, is proven to be one of the promising candidates for electronic assembly. Previous work also revealed that adding a small amount of rare earth Ce into SnAgCu solder can visibly improve the properties and inhibit the excessive growth of the intermetallic compound layer. Thermal fatigue properties of SnAgCuCe soldered joints in QFP devices under thermal conditions have been investigated by finite element method and experiments. Based on creep model of low stress and high stress, corresponding creep subroutine was established for simulating the stress and strain response of SnAgCuCe soldered joint from -55 ℃ to 125 ℃, and fatigue life was calculated using creep fatigue life prediction equation. Moreover, thermal cycling experiments were conducted, the experimental results were found to be close to the simulated results. In addition, the tensile force of SnAgCuCe soldered joints decreased with increasing number of thermal cycles, and the fracture mechanism transformed from toughness fracture to brittle intergranular fracture. Moreover the tensile force changes and fracture microstructure evolution could benefit the quantitative evaluations of the mechanical performances of lead-free soldered joints under thermal cycling loadings.

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 OF HIGH TEMPERATURE STRUCTURAL COMPONENT BY STRAIN RANGE PARTITIONING

The s recent works on the improvement of the Strain Range Partitioning(SRP) method and its application to the life prediction of high temperature structural components are summarized. Examined components are divided into three groups, that is, components in the steel production plants, in the automobile and in the fossil power plants. Based on the results of the inelastic analysis and the creepfatigue properties of the material, which were obtained by IJ(=PP,PC, CP, CC) tests, the effects of the material properties, operating conditions and configuration of components were quantitatively evaluated to select the most effective measures for the thermal fatigue life extension. The SRP has been successfully applied until now to the life prediction and extension of the actual structural components subjected to thermal cycling by the s.

Study on Higher Efficiency Thermal Cycling Profile for HALT

HALT(highly accelerated life test) is a new reliability test technique.This paper uses nonlinear finite element method to analyze the stress strain characteristic of solder joints of PQFP(plastic quad flat packaging) and BGA(ball grid array) under thermal cycle test,and studies influences of profile parameters of the thermal cycle,such as hot and cold soak temperature,hot and cold soak time and temperature change rate,on elastic strain range,accumulated plastic strain,fatigue life and test efficiency of two types of solder joints.Based on the above research and experimental verification,this paper presents the method to build an optimal thermal cycling profile for HALT of electronic components.

Effects of Ambient Temperature and Shaft Power Variations on Creep Life Consumption of Industrial Gas Turbine Blades

The effects of ambient temperature and shaft power variations on creep life consumption of compressor turbine blades of LM2500+ industrial gas turbine engine are investigated in this work. An engine model was created in PYTHIA (Cranfield University’s gas turbine software) for the analysis. Blade thermal and stress models were developed and used together with Larson-Miller Parameter method for life analysis. Mean life reduction index, which is the propensity of a given effect to reduce engine life by half, is developed for each effect and applied in this research to compare the impacts of the different effects on the blade creep life. It was observed that blade life will be halved when ambient temperature is increased by 8.11 units while 13.64% increase in shaft power reduces blade life by a factor of 2. The results of this work will guide engine operators in making decisions concerning operating at part loads.

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...

残余应力对GH3230层板焊缝热疲劳寿命影响规律研究

为了探究残余应力对层板冷却结构焊缝服役寿命的影响规律,首先对GH3230层板在常规条件下的激光焊接过程进行有限元模拟与实验验证,然后在此基础上对预拉伸、温差拉伸等焊接残余应力调控方法开展模拟。基于焊后残余应力模拟结果研究了层板服役过程的温度及等效应力变化规律,并将多个模型之间不同残余应力下服役状态进行对比分析,最后利用Morrow修正的Coffin-Manson方程对焊缝后续服役寿命进行评估。研究结果表明,焊接残余应力的存在大幅降低了层板结构焊缝区域热疲劳寿命,通过残余应力调控技术可有效改善焊缝区域服役过程中的应力幅或平均应力,使其分别下降70%与25%,焊接残余应力调控对提高层板结构热疲劳寿命具有重要意义。

FAILURES AND THE LIFE OF FURNACE TUBES

It is showed after the furnace tubes serviced for 8-10 years that the density of damage in the HAZ (heat affected zone) of the weld has higher than in parent metals, though the depth of damage is not equal to. By the test of creep crack growth, it is also acquired that under same mechanic parameter C* (t), the rate of creep crack growth in the HAZ is more than twice as fast as in parent metals. Two mechanisms (overheating and thermal shock) of failure occurred in an accident are presented. The stress of thermal shock is analyzed, in which the change of the elasticity modulus with the radius ET = /(r) is considered. Based on it, the safety region of the thermal shock is obtained. Finally, two sets of curves for the safe life are suggested which can facilitate to estimate the remaining life of HK-40 or HP-Nb tubes by their creep rupture data.

Performance Survey of PVC Insulation of LC/Gecamines Electrical Cables Subjected to Ageing and Its Life Span Evaluation

Considering the insulators ageing in a mixture of PVC and dye, set following operating conditions and time to ensure proper operation and perfect safety of industrial installations using insulated conductors. The results showed that the insulation carried out by the L.C main office was a good quality (on thermal aspect), because the resistance of the insulation is so high (i.e. 3940 Mega Ohms under normal conditions). The results showed a lifespan of 50 years at a temperature of 40°C (close to ambient temperature), plus minus 33 years at a temperature of 70°C;plus minus 22 years at a temperature of 100°C and 12 years at a temperature of 160°C. Furthermore, information on chemical attack, the results showed that PVC cables have poor resistance to sulfuric acid attack (having a pH of 1.5 and a density of 1.84 g/cm3). LC/Gecamines is able to produce locally a good quality of electrical cables.