Enhancing fatigue performance of AZ31 magnesium alloy components fabricated by cold metal transfer-based wire arc directed energy deposition through LPB

Cold Metal Transfer-Based Wire Arc Directed Energy Deposition(CMT-WA-DED)presents a promising avenue for the rapid fabrication of components crucial to automotive,shipbuilding,and aerospace industries.However,the susceptibility to fatigue of CMT-WA-DED-produced AZ31 Mg alloy components has impeded their widespread adoption for critical load-bearing applications.In this study,a comprehensive investigation into the fatigue behaviour of WA-DED-fabricated AZ31 Mg alloy has been carried out and compared to commercially available wrought AZ31 alloy.Our findings indicate that the as-deposited parts exhibit a lower fatigue life than wrought Mg alloy,primarily due to poor surface finish,tensile residual stress,porosity,and coarse grain microstructure inherent in the WA-DED process.Low Plasticity Burnishing(LPB)treatment is applied to mitigate these issues,which induce significant plastic deformation on the surface.This treatment resulted in a remarkable improvement of fatigue life by 42%,accompanied by a reduction in surface roughness,grain refinement and enhancement of compressive residual stress levels.Furthermore,during cyclic deformation,WA-DED specimens exhibited higher plasticity and dislocation density compared to both wrought and WA-DED+LPB specimens.A higher fraction of Low Angle Grain Boundaries(LAGBs)in WA-DED specimens contributed to multiple crack initiation sites and convoluted crack paths,ultimately leading to premature failure.In contrast,wrought and WA-DED+LPB specimens displayed a higher percentage of High Angle Grain Boundaries(HAGBs),which hindered dislocation movement and resulted in fewer crack initiation sites and less complex crack paths,thereby extending fatigue life.These findings underscore the effectiveness of LPB as a post-processing technique to enhance the fatigue performance of WA-DED-fabricated AZ31 Mg alloy components.Our study highlights the importance of LPB surface treatment on AZ31 Mg components produced by CMT-WA-DED to remove surface defects,enabling their widespread use in load-bearing applications.

Effects of installations on the low frequency vibration response of specimens in acoustic fatigue tests

The low frequency vibration response of a specimen in acoustic fatigue tests depends not only on the dynamic characteristics and the boundary conditions of the specimen itself, but also on the test unit which couples the specimen to a given sound field. Further, the latter can even be dominant instead the former in some circumstances. This fact is shown in the paper by using the experimental results and the theoretical analysis of the acoustic-induced vibration of a boundary clamped rectangular thin plate. In analysing the systems of acoustic fatigue test, an approach of electro-mechano-acoustical analogous circuit is used. The application of the approach can give an estimation of the effects on the low frequency vibration modes of various parameters in a system quantitatively. This supplies a theoretical basis and a means for the rational layout of acoustic fatigue tests.

Stiffness Degradation Modeling for Composite Wind Turbine Blades Based on Full-Scale Fatigue Testing

In order to provide more insights into the damage propagation composite wind turbine blades(blade)under cyclic fatigue loading,a stiffness degradation model for blade is proposed based on the full-scale fatigue testing of a blade.A novel non-linear fatigue damage accumulation model is proposed using the damage assessment theories of composite laminates for the first time.Then,a stiffness degradation model is established based on the correlation of fatigue damage and residual stiffness of the composite laminates.Finally,a stiffness degradation model for the blade is presented based on the full-scale fatigue testing.The scientific rationale of the proposed stiffness model of blade is verified by using full-scale fatigue test data of blade with a total length of 52.5 m.The results indicate that the proposed stiffness degradation model of the blade agrees well with the fatigue testing results of this blade.This work provides a basis for evaluating the fatigue damage and lifetime of blade under cyclic fatigue loading.

Fatigue test loading methodfor wagon body basedon measured load

Purpose–In this paper,the C80 special coal gondola car was taken as the subject,and the load test data of the car body at the center plate,side bearing and coupler measured on the dedicated line were broken down to generate the random load component spectrums of the car body under five working conditions,namely expansion,bouncing,rolling,torsion and pitching according to the typical motion attitude of the car body.Design/methodology/approach–On the basis of processing the measured load data,the random load component spectrums were equivalently converted into sinusoidal load component spectrums for bench test based on the principle of pseudo-damage equivalence of load.Relying on the fatigue and vibration test bench of the whole railway wagon,by taking each sinusoidal load component spectrum as the simulation target,the time waveform replication(TWR)iteration technology was adopted to create the drive signal of each loading actuator required for the fatigue test of car body on the bench,and the drive signal was corrected based on the equivalence principle of measured stress fatigue damage to obtain the fatigue test loads of car body under various typical working conditions.Findings–The fatigue test results on the test bench were substantially close to the measured test results on the line.According to the results,the relative error between the fatigue damage of the car body on the test bench and the measured damage on the line was within the range of
16.03%–27.14%.Originality/value–The bench test results basically reproduced the fatigue damage of the key parts of the car body on the line.

ESTIMATION OF FATIGUE LIFE UNDER RANDOM LOADING WITH PLASTIC HYSTERESIS ENERGY THEOREM

Fatigue damage of materials includes static damage and cyclic damage.Static damage is a ratio of the plastic energy in first static loading to the statictoughness, while cyclic damage is the ratio of the cyclic plastic hysteresis energy to thefatigue toughness. In the calculation, cyclic hardening (or softening) of a material istaken into account, which results in the increase (or decrease) of the yield stress. Forsimplification, it is assumed that stress and strain in cyclic loading vary in accordancewith the hysteresis loop. Fatigue toughness of a material can be detennined bysymmetric cyclic stress controlled fatigue test. A method, rational and convenient forengineering, is proposed to estimate the fatigue life under random loading based onplastic hysteresis energy theorem. Preliminary verification by test is satisfactory.

EFFECT OF FRICTIONAL FORCE ON GEARING CONTACT FATIGUE STRENGTH

The model for computing frictional coefficient between two teeth faces at the state of mixed elastohydrodynamic lubrication is established. And then more than 80 sets of numerical calculations and six sets of disc fatigue tests are completed. The results show that when the film thickness ratio λ 〈1.6, frictional coefficient μ is drastically decreased as λ. rises; Thereafter it decreases smoothly until λ=4.5. When λ〉4.5, however, it goes up again with λ, which indicates that the excessive film thickness ratio will deteriorate gearing contact fatigue strength. At the end, the formulae for determining the frictional coefficients are formed.

A NOVEL PARAMETER FOR EVALUATING THE FATIGUE CRACK GROWTH RATE IN CARBON STEELS

A novel parameter is suggested for evaluating the fatigue crack growth rate in carbon steels. Fatigue crack propagation tests of an annealed 0.42% carbon steel were carried out under different conditions to investigate the relationship between this dominating parameter and the crack opening displacement (COD). A new equation of fatigue crack growth rate is formulated in terms of the suggested parameter. The physical meanings of the material parameters in this equation are explored experimentally. Considering the relation of crack growth and deformation properties, a simple and applicable method is proposed to evaluate the fatigue crack growth rate. It is also observed that the material parameters in the fatigue crack growth rate equation of carbon steels are related linearly to the material strength. The results are in a good agreement with experimental results.

Effects of Strain Ratio on Fatigue Behavior of G20Mn5QT Cast Steel

Due to traffic and wave actions, cast steel joints are subjected to variable-amplitude fatigue loading, which may cause fatigue problems. The ratio of the minimum strain to the maximum strain(strain ratio)can be employed to analyze the influence of variable-amplitude fatigue both in the elastic and plastic ranges. To evaluate the effect of the strain ratio on G20Mn5 QT cast steel, the fatigue tests of smooth specimens were carried out at the strain ratio of 0.1. The cyclic deformation and the relationships between the strain amplitude, the stress amplitude, the Smith, Watson and Topper(SWT)parameter and fatigue life were studied and compared with those at the strain ratio of-1. Compared with other methods, Basquin formula and Solonberg formula provide reliable and appropriate ranges of S-N curve and fatigue limit at different strain ratios respectively. The SWT parameter can be used to predict the fatigue life at other strain ratios accurately.

Fatigue Characterization on a Cast Aluminum Beam of a High-Speed Train Through Numerical Simulation and Experiments

The cast aluminum beam is a key structure for carrying the body-hung traction motor of a high-speed train;its fatigue property is fundamental for predicting the residual life and service mileage of the structure.To characterize the structural fatigue property,a finite element-based method is developed to compute the stress concentration factor,which is used to obtain the structural fatigue strength reduction factors.A full-scale fatigue test on the cast aluminum beam is designed and implemented for up to ten million cycles,and the corresponding finite element model of the beam is validated using the measured data of the gauges.The results show that the maximum stress concentration occurs at the fillet of the supporting seat,where the structural fatigue strength reduction factor is 2.45 and the calculated fatigue limit is 35.4 MPa.Moreover,no surface cracks are detected using the liquid penetrant test.Both the experimental and simulation results indicate that the cast aluminum beam can satisfy the service life requirements under the designed loading conditions.

FATIGUE LIVES FOR INDUCTION HARDENED SHAFTS MATERIALS ACCORDING TO THE ENVIRONMENTAL TEMPERATURES

Rotary bending fatigue tests were carried out with two kinds of materials, S43C and S50C, using the front engine and front drive shaft （FF shaft） of vehicle. The specimens were induction hardened about 1.0mm depth from the specimen surface, and the hardness value on the surface was about HRC56-60. The tested environment temperatures were -30, 25 and 80℃ in order to look over effect of the induction hardening and the environmental temperatures on the fatigue characteristics. The fatigue limit of induction hardened specimens increased more about 45% than non-hardened specimens showing that the endurances of S43C and S50C were 98.1 and 107.9MPa in non-hardened samples, 147.1 and 156.9MPa in hardened samplesrespectably. The maximum tensile and compressive stress on the small circular defect was about ＋250 and -450MPa respectively when circular defect is situated on top and bottom. The fatigue life increased 80, 25 and -30℃ in order regardless of hardening. In comparison of the fatigue lives on the basis of tested result at 25℃, the fatigue lives of non-hardened specimens decreased about 35%, but that of hardened specimens decreased about only 5% at 80℃ more than at 25℃. And fatigue life of non-hardened and hardened specimens were about 110% and 120% higher at -30℃ than that of 25℃. Based on the result of stress distribution near the defect, the tensile and compressive stress repeatedly generated by load direction were the largest on the small circular defect due to the stress concentration.

Flexural Fatigue Behavior of Layered Hybrid Fiber Reinforced Concrete

In order to obtain the fatigue life of layered hybrid fiber reinforced concrete （LHFRC） at different stress levels, flexural fatigue tests were carried out on specimens. The relation between fatigue lives and stress levels was simulated using the two-parameter Weibull distribution. Furthermore, both single- logarithmic and double-logarithmic regressive equations of various reliabilities were derived. It is evident that LHFRC gets the advantage of longer fatigue life over common concrete.

Current understanding of ultra-high cycle fatigue

The fatigue life of numerous aerospace,locomotive,automotive and biomedical structures may go beyond 10~8 cycles.Determination of long life fatigue behavior becomes extremely important for better understanding and design of the components and structures.Initially,before the invention of ultrasonic fatigue testing,most of the engineering materials were supposed to exhibit fatigue life up to 10~7 cycles or less.This paper reviews current understanding of some fundamental aspects on the development of accelerated fatigue testing method and its application in ultra-high cycle fatigue,crack initiation and growth mechanisms of internal fracture,S-N diagram,fatigue limit and life prediction, etc.

Fatigue Test of Homemade Z Direction Steel Welded T Tubular Joints

This paper introduces the process and result of fatigue test of steel (Z direction steel) welded T tubular joints used in offshore engineering. Detailed measurement of stress concentration factor, stress distribution, fatigue life and crack development has been performed. Through analysis, an empirical formula of stress concentration factor for T tubular joints, fatigue S-N curve and crack propagation rule are obtained.

Seawater Corrosion Fatigue of Welded Joints Under Random Variable Amplitude Loading

Offshore platforms are always subjected to wave action which is random variable amplitude cyclic loading. In order to simulate the stressing condition at the 'hot spot' of the tubular joints and the marine environment, random variable amplitude fatigue tests have been carried out on welded plate joints in sea water. The tests have been conducted under the conditions of loading frequency of 0.2 Hz/, stress ratio of -1, seawater temperature of about 20°C and cathodic protection with the potential about -850 mV, SCE. The test results have been compared with the seawater corrosion fatigue life under constant amplitude loading. Miner's linear cumulative damage summation rule has been used to predict the corrosion fatigue life under variable amplitude loading. The predicted life is in good agreement with the test data.

SHORT FATIGUE CRACK PARAMETER BASED ON THE TOTAL CRACK AREA

The progressive fatigue damage of a material is closely related to the whole population of cracks on its surface. In order to understand which parameter is a more useful indicator of fatigue damage, rotatory bending fatigue tests were carried out using smooth specimens of medium-carbon steel. The behavior of short crack propagation during fatigue was examined and a new parameter total crack area was suggested. The aim of this paper is to extend the research on fatigue damage in the already studied steel and to study how these damage parameters are correlated with the process of fatigue damage in order to evaluate the effectiveness of damage detection methods.

SIMULATION OF COMPLEX THERMOMECHANICAL FATIGUE

Two different types of experimental techniques to perform non-isothermal, uniax-ial and biaxial fatigue tests were described. A new miniaturised electrothermal-mechanical test rig was presented and discussed. It enables testing of small specimens under complex thermomechanical loading conditions. In order to cope with the simulation of well defined biaxial proportional and non-proportional loadings with in-phase and out-of-phase superposition of thermal loads a cruciform biaxial fatigue testing machine has been developed. Special design features of both machines, and the specimens tested, as well as typical test results were discussed.

Quality Evaluation of Diffusion Bonded Joints by Electrical Resistance Measuring and Microscopic Fatigue Testing

Micro-structure related behavior of diffusion bonding joints is a crucial issue in device and reactor fabrication of Micro Chemo Mechanical Systems.However,the previous studies have been focused on the macro mechanical performance of diffusion bonded joint,especially diffusion bonding conditions effects on tensile strength,shearing strength and fatigue strength.The research of interfacial micro-voids and microstructures evolution for failure mechanism has not been carried out for diffusion-bonded joints.An interfacial electrical resistance measuring method is proposed to evaluate the quality of bonded joints and verified by using two-dimensional finite-element simulation.The influences of micro void geometry on increments of resistance are analyzed and the relationship between bonded area fraction and resistance increment is established by theoretical analysis combined with simulated results.Metallographic inspections and micro-hardness testing are conducted near the interface of diffusion bonded joints.For the purpose of identifying the failure mechanisms of the joints,both microscopic tensile and fatigue tests are conducted on the self-developed in-situ microscopic fatigue testing system.Based on the microscopic observations,the mechanism of interfacial failure is addressed.The observation result shows that for 316LSS diffusion-bonded joints,microstructure evolution and effect of micro-voids play a key role in interfacial failure mechanism.Finally,a new life prediction model in terms of the increment of electrical resistance is developed and confirmed by the experimental results.The proposed study is initiated that constituted a primary interfacial failure mechanism on micron scale and provide the life prediction for reliability of components sealed by diffusion bonding.

EFFECT OF FABRICATION ON HIGH CYCLE FATIGUE PROPERTIES OF COPPER THIN FILMS

The influence of fabrication on the tensile and fatigue behavior of copper films manufactured by 3 kinds of fabrication methods was investigated. The tensile and high cycle fatigue tests were performed using the test machine developed by authors. Young＇s moduli （72, 71 and 69 GPa, respectively） are lower than the literature values （108-145 GPa）, while the yield strengths were as high as 358, 350 and 346 MPa, respectively and the ultimate strengths as 462, 456 and 446 MPa, respectively. There is not much difference in the tensile properties of the 3 kinds of films. There is little difference in the fatigue properties of the 3 kinds of films but one of them has shorter fatigue life than others in high cycle region and longer fatigue life than others in low cycle region.

Research and Analysis on Tensile and Compressive Fatigue Performance of Cryogenic Axial Insulation Breaks

The composite axial insulation breaks （IBs） are key components of the supercon- ducting magnet system for the international thermonuclear experimental reactor （ITER）. In order to ensure the safe operation of the IBs during the 20 year lifespan of ITER devices, tensile and compressive fatigue tests were conducted by simulating actual working conditions and optimizing the test programs. The IBs were evaluated by testing their helium tightness after mechanical fatigue tests. In addition, fatigue analysis was performed using ANSYS software and an experi-mental S-N curve. The test data showed that the maximum helium leakage rate was less than 1.0×10^-9 Pc· m^3/s, which met the design requirements of the ITER IBs. ANSYS analysis results are also consistent with the test results from the theoretical viewpoint.

High cycle fatigue life prediction method for tail gearbox casing of a helicopter transmission system

A method and procedure of high cycle fatigue life prediction for helicopter transmission system tail gearbox casing is presented, including fatigue test load, three parameters S-N curve, reduction factor and cumulative damage law. According to the fatigue test results, the design load spectrum and the three parameters S-N curve, a fatigue life prediction of the tail gearbox casing of a helicopter is performed as an example.