Remaining Useful Life for Heavy-Duty Railway Cast Steel Knuckles Based on Crack Growth Behavior with Hypothetical Distributions

The current research on the integrity of critical structures of rail vehicles mainly focuses on the design stage,which needs an effective method for assessing the service state.This paper proposes a framework for predicting the remaining useful life(RUL)of in-service structures with and without visible cracks.The hypothetical distribution and delay time models were used to apply the equivalent crack growth life data of heavy-duty railway cast steel knuckles,which revealed the evolution characteristics of the crack length and life scores of the knuckle under different fracture failure modes.The results indicate that the method effectively predicts the RUL of service knuckles in different failure modes based on the cumulative failure probability curves for different locations and surface crack lengths.This study proposes an RUL prediction framework that supports the dynamic overhaul and state maintenance of knuckle fatigue cracks.

Effects of orientation on the fatigue crack growth behaviors of the ZK60 magnesium alloy in air and PBS

Strong anisotropic corrosion and mechanical properties caused by specimen orientations greatly limit the applications of wrought magnesium alloys.To investigate the influences of specimen orientation,the corrosion tests and(corrosion)fatigue crack growth tests were conducted.The rolled and transverse surfaces of the materials show distinct corrosion rate differences in the stable corrosion stage,but the truth is the opposite for the initial stage of corrosion.In air,specimen orientations have a significant influence on the plastic deformation mechanisms near the crack tip,which results in different fatigue fracture surfaces and cracking paths.Compared with R-T specimens,N-T specimens show a slower fatigue crack growth(FCG)rate in air,which can be attributed to crack closure effects and deformation twinning near the crack tip.The corrosion environment will not significantly change the main plastic deformation mechanisms for the same type of specimen.However,the FCG rate in phosphate buffer saline(PBS)is one order of magnitude higher than that in air,which is caused by the combined effects of hydrogen-induced cracking and anodic dissolution.Owing to the similar corrosion rates at crack tips,the specimens with different orientations display close FCG rates in PBS.

Crack Growth Rate Model Derived from Domain Knowledge-Guided Symbolic Regression

Machine learning(ML)has powerful nonlinear processing and multivariate learning capabilities,so it has been widely utilised in the fatigue field.However,most ML methods are inexplicable black-box models that are difficult to apply in engineering practice.Symbolic regression(SR)is an interpretable machine learning method for determining the optimal fitting equation for datasets.In this study,domain knowledge-guided SR was used to determine a new fatigue crack growth(FCG)rate model.Three terms of the variable subtree ofΔK,R-ratio,andΔK_(th)were obtained by analysing eight traditional semi-empirical FCG rate models.Based on the FCG rate test data from other literature,the SR model was constructed using Al-7055-T7511.It was subsequently extended to other alloys(Ti-10V-2Fe-3Al,Ti-6Al-4V,Cr-Mo-V,LC9cs,Al-6013-T651,and Al-2324-T3)using multiple linear regression.Compared with the three semi-empirical FCG rate models,the SR model yielded higher prediction accuracy.This result demonstrates the potential of domain knowledge-guided SR for building the FCG rate model.

Statistical learning prediction of fatigue crack growth via path slicing and re-weighting

Predicting potential risks associated with the fatigue of key structural components is crucial in engineering design.However,fatigue often involves entangled complexities of material microstructures and service conditions,making diagnosis and prognosis of fatigue damage challenging.We report a statistical learning framework to predict the growth of fatigue cracks and the life-to-failure of the components under loading conditions with uncertainties.Digital libraries of fatigue crack patterns and the remaining life are constructed by high-fidelity physical simulations.Dimensionality reduction and neural network architectures are then used to learn the history dependence and nonlinearity of fatigue crack growth.Path-slicing and re-weighting techniques are introduced to handle the statistical noises and rare events.The predicted fatigue crack patterns are self-updated and self-corrected by the evolving crack patterns.The end-to-end approach is validated by representative examples with fatigue cracks in plates,which showcase the digital-twin scenario in real-time structural health monitoring and fatigue life prediction for maintenance management decision-making.

Probability estimation method for fatigue crack growth rate based on a∼t data from service

Purpose–The study aims to provide a basis for the effective use of safety-related information data and a quantitative assessment way for the occurrence probability of the safety risk such as the fatigue fracture of the key components.Design/methodology/approach–The fatigue crack growth rate is of dispersion,which is often used to accurately describe with probability density.In view of the external dispersion caused by the load,a simple and applicable probability expression of fatigue crack growth rate is adopted based on the fatigue growth theory.Considering the isolation among the pairs of crack length a and crack formation time t(a∼t data)obtained from same kind of structural parts,a statistical analysis approach of t distribution is proposed,which divides the crack length in several segments.Furthermore,according to the compatibility criterion of crack growth,that is,there is statistical development correspondence among a∼t data,the probability model of crack growth rate is established.Findings–The results show that the crack growth rate in the stable growth stage can be approximately expressed by the crack growth control curve da/dt=5 Q•a,and the probability density of the crack growth parameter Q represents the external dispersion;t follows two-parameter Weibull distribution in certain a values.Originality/value–The probability density f(Q)can be estimated by using the probability model of crack growth rate,and a calculation example shows that the estimation method is effective and practical.

Finite Element Analysis on Plane Stress Crack Growth in a Power-Law Hardening Material

Aim To determine numerically the field characteristics in the vied at the tip of a place crack growing steadily in a power-law hardening material. Meteods. Methods on the Euler mode and small-scale yield assumption, the numerical results were given by nonlinear finite element analysis. Results The numerical results of the shape of the active plastic sone, the angular distribution of stresseses and Clack tip opening displacement (CTOD) in the vicinity at the hp of the steadily groWing CraCk are determined. Conclusion The comparison between the numerical results given by the present wort and those given by analytic asymptotic analysis shows that the present work reached a very high accuracy.

A GENERAL CONSTITUTIVE RELATION FOR FATIGUE CRACK GROWTH ANALYSIS OF METAL STRUCTURES

Crack growth rate curves are the fundamental material property for metal structures under fatigue loading. Although there are many crack growth rate curves available in the literature, few of them showed the capability to explain various special phenomena observed in tests. A modified constitutive relation recently proposed by McEvily and his co-workers showed very promising capability. This modified constitutive relation is further generalized by (1) introducing an unstable fracture condition; (2) defining a virtual strength to replace the yield stress; and (3) defining an overload and underload parameter. The performances of this general constitutive relation for fatigue crack growth is extensively studied and it is found that this general constitutive relation is able to explain various phenomena observed with particular strong capability on load sequence effect.

DEVELOPMENT OF INCONEL~ ALLOY 783，A LOW THERMAL EXPANSION，CRACK GROWTH RESISTANT SUPERALLOY

Low thermal expansion superalloys have been used for a number of years in a variety of applications, including gas turbine engines. The low thermal expansion characteristics of the most widely used class of materials are derived from the ferromagnetic characteristics of Ni, Fe, and Co-based austenitic matrices containing little or no Cr.Alloy developments have been aimed at improving the oxidation resistance and stress accelerated grain boundary oxygen (SAGBO) attack.INCONEL alloy 783 is an oxidation resistant, low coefficient of thermal expansion superalloy developed for gas turbine applications. Alloy 783 represents a culmination in the development, of an alloy system with very high alumtnum content that, in addition to forming γ′,causes βaluminide phase precipitation in the austenitic matrix.This type of structure can be processed to resist both SAGBO and general oxidation,while providing low thermal expansion and useful mechanical properties up to 700℃.Key aspects of the alloy's development are presented.

Effects of precipitates on fatigue crack growth rate of AA 7055 aluminum alloy

The effects of precipitates on the fatigue crack growth rate of AA 7055 Al alloy subjected to different ageing treatments were investigated using transmission electron microscope and fatigue crack growth testing.The results show that the T77 treated samples exhibit the lowest crack growth rate,while the crack growth rate of over-aged samples is the highest.In terms of the model based on the reversibility of dislocation motion within the plastic zone close to the crack tip,the improved crack growth resistance is attributed to many precipitates that are coherent with Al matrix in the under-aged and T77 treated samples.When the precipitate is coherent with the Al matrix,the larger the precipitate is,the slower the fatigue crack grows.The effects of grain boundary precipitates and precipitate free zone on the fatigue crack growth resistance are less significant than those of precipitates within grains of the alloy.

Effect of annealing treatment on microstructure and fatigue crack growth behavior of Al–Zn–Mg–Sc–Zr alloy

Al-Zn-Mg-Sc-Zr alloy samples were annealed to four different states （under-aging, peak-aging, over-aging and double-aging） and then thoroughly investigated by means of electron backscatter diffraction （EBSD）, transmission electron microscopy （TEM）, scanning electron microscopy （SEM）, tensile and fatigue crack growth rate tests to explore the influence of annealing treatment on microstmcture and fatigue crack growth behavior. The results indicate that Al3（Sc,Zr） particles can effectively refine grains and enhance tensile properties and fatigue properties. After annealing treatment, the under-aged sample and double-aged sample obtained average grain sizes of 4.9473 and 4.1257 μm, and the maximum value of yield/tensile strength （561 MPa/581 MPa） was obtained in peak-aged state. In the Paris region, fatigue crack growth rate, crack deflection and bifurcation, crack blunting and inter/trans-granular propagation were discussed based on data fitting and Laird model and Griffith theory. And the results show that the under-aged sample possesses the best resistance to fatigue crack propagation and the most tortuous and bifurcated crack path. For all samples, the fatigue crack growth rate in the rupture region was inversely proportional to yield strength.

Test of subcritical crack growth and fracture toughness under water-rock interaction in three types of rocks

The subcritical crack growth and fracture toughness in peridotite, lherzolite and amphibolite were investigated with double torsion test. The results show that water-rock interaction has a significant influence on subcritical crack growth. With water-rock interaction, the crack velocity increases, while the stress intensity factor declines, which illustrates that water-rock interaction can decrease the strength of rocks and accelerate the subcritical crack growth. Based on Charlse theory and Hilling & Charlse theory, the test data were analyzed by regression and the correlation coefficients were all higher than 0.7, which shows the correlation is significant. This illustrates that both theories can explain the results of tests very well. Therefore, it is believed that the subcritical crack growth attributes to the breaking of chemical bond, which is caused by the combined effect of the tensile stress and the chemical reaction between the material at crack tip and the corrosive agent. Meanwhile, water-rock interaction has a vital effect on fracture toughness. The fracture toughness of samples under atmospheric environment is higher than that of samples immersed in water. And water-rock interaction has larger influence on fracture toughness in amphibolite than that in peridotite and lherzolite.

Fatigue Crack Growth Rate of Ti-6Al-4V Considering the Effects of Fracture Toughness and Crack Closure

Fatigue fracture is one of the main failure modes of Ti-6A1-4V alloy,fracture toughness and crack closure have strong effects on the fatigue crack growth（FCG）rate of Ti-6A1-4V alloy.The FCG rate of Ti-6A1-4V is investigated by using experimental and analytical methods.The effects of stress ratio,crack closure and fracture toughness on the FCG rate are studied and discussed.A modified prediction model of the FCG rate is proposed,and the relationship between the fracture toughness and the stress intensity factor（SIF）range is redefined by introducing a correcting coefficient.Notched plate fatigue tests（including the fracture toughness test and the FCG rate test）are conducted to investigate the influence of affecting factors on the FCG rate.Comparisons between the predicted results of the proposed model,the Paris model,the Walker model,the Sadananda model,and the experimental data show that the proposed model gives the best agreement with the test data particularly in the near-threshold region and the Paris region,and the corresponding calculated fatigue life is also accurate in the same regions.By considering the effects of fracture toughness and crack closure,the novel FCG rate prediction model not only improves the estimating accuracy,but also extends the adaptability of the FCG rate prediction model in engineering.

Effects of pre-rolling on mechanical properties and fatigue crack growth rate of 2195 Al-Li alloy

While pre-deformation is often conducted before aging treatment to increase the strength and microhardness of 2195 Al-Li alloy, it often increases the fatigue crack growth(FCG) rate and thus reduces the fatigue life of the alloy.To determine the effects and causes of pre-deformation and heat treatment on the mechanical properties and FCG rate of2195 Al-Li alloy, and to provide a suitable calculation model for the FCG rate under different pre-deformation conditions, 2195 Al-Li alloy specimens with different degrees of pre-rolling(0, 3%, 6%, and 9%) were investigated. The experimental results indicate that with the increase of pre-rolling, the density of the T1phase and the uniformity of the S′distribution and the microhardness, tensile strength, and yield strength of the alloy increase and at the same time the FCG rate increases, and thus the fatigue life is reduced. It was also found that the normalized stress intensity factor of elastic modulus(E) can be applied to correlate the FCG rate of pre-rolled 2195 Al-Li alloy with constant C and K parameters.

EFFECTS OF MICROSTRVCTURE ON FATIGUE CRACK GROWTH BEHMIOR IN Ni-BASE SUPERALLOY GH586

Threshold stress values, muging from ～8 to 16MPa·m1/2 can be obtained in a Ni-base alloy GH586 by varying the microstructure through heat treatments. The threshold and low crack growth rate behaviors at room temperature, with varying groin size and γ'-distribution, have been investigated. The results indicate that grain size is an important microstructurol parameter that affects fatigue crack growth threshold and propagation behaviors, as the values of △Kth increase with increasing grain size, but the γ' -distribution also has important effect. Analyses show that the effects of groin size on threshold and low crack-growth rate behavior result from heterogeneous deformation and roughness-induced crack closure due to crystallographic slipping and cracking in coarse microstructure. The higher △Kth and lower fatigue crack growth rate with increasing amounts of fine γ' phases are closely related to less damage accumulation level in deformation zone of crack-tip resulted from heterogeneous deformation due to dislocations' shearing γ' precipitates.

Effect ofαphase morphology on fatigue crack growth behavior of Ti−5Al−5Mo−5V−1Cr−1Fe alloy

Taking a Ti−5Al−5Mo−5V−1Cr−1Fe alloy as exemplary case,the fatigue crack growth sensitivity and fracture features with various tailoredαphase morphologies were thoroughly investigated using fatigue crack growth rate(FCGR)test,optical microscopy(OM)and scanning electron microscopy(SEM).The tailored microstructures by heat treatments include the fine and coarse secondaryαphase,as well as the widmanstatten and basket weave features.The sample with coarse secondaryαphase exhibits better comprehensive properties of good crack propagation resistance(with long Paris regime ranging from 15 to 60 MPa·m1/2),high yield strength(1113 MPa)and ultimate strength(1150 MPa),and good elongation(11.6%).The good crack propagation resistance can be attributed to crack deflection,long secondary crack,and tortuous crack path induced by coarse secondaryαphase.

Fatigue crack growth behaviour of friction stir welded AA7075-T651 aluminium alloy joints

The aim of the present work is to evaluate the fatigue crack growth behaviour of 12 mm thick AA 7075-T651 aluminium alloy plates joined by FSW. Fatigue crack growth test was carried out on center cracked tensile (CCT) specimens extracted from the FSW joints and unwelded parent metal. Transverse tensile properties of the unwelded parent metal and welded joints were evaluated. Microstructures of the welded joints were analyzed using optical microscopy and transmission electron microscopy. The scanning electron microscope was used to characterize the fracture surfaces. It was found that the ΔKcr of the welded joint is reduced by 10×10-3 MPa·m1/2 in comparison with the unwelded parent metal. Hence, the fatigue life of the friction stir welded AA 7075-T651aluminium alloy joints is appreciably lower than that of the unwelded parent metal, which is attributed to the dissolution of precipitates in the weld region during friction stir welding.

EFFECTS OF STRESS RATIO AND FREQUENCY ON CORROSION FATIGUE CRACK GROWTH MECHANISM IN LOW ALLOY STEELS

Based on theoretical analysis about local strain,strain rate and dissolving rate at crack tip, the corrosion fatigue crack growth rate of steels ZG20SiMn and SM50B-Zc in fresh water and 3.5% NaCl solution were measured experimentally,and the PH and electrode potential within crack were also measured continuously along with crack propagating.It showed that the increase of crack growth rate,caused by both decreasing frequency and raising stress ratio,was mainly accelerated by hydrogen embrittlement.

Simple Predicting Method for Fatigue Crack Growth Rate Based on Tensile Strength of Carbon Steel

Three types of fatigue tests for an annealed carbon steel containing carbon of 0.42%were carried out on smooth specimens and specimens with a small blind hole in order to investigate the fatigue crack growth law.A simple predicting method for crack growth rates has been proposed involving strengthσband the relation between cyclic stress and strain.The validity of proposed method has been confirmed by experiments on several carbon steels with different loadings.

Fracture toughness and fatigue crack growth analysis of 7050-T7451 alloy thick plate with different thicknesses

The strength, fracture toughness and fatigue crack growth resistance of 7050-T7451 aluminum alloy plate with different thicknesses （35 mm and 160 ram） were investigated by means of optical microscope, scanning electron microscope and transmission electron microscope. The results show that thicker plate has lower strength and fracture toughness but higher fatigue crack growth resistance, by comparison to the thinner plate. The drop of strength is mainly attributed to grain coarsening in the thicker plate, and the increased degree of recrystallization results in the loss of Kio However, the coarsened grains in the thicker plate make cracks deflected and closure effect enhanced due to surface roughness increased. For both of plates, in the fracture surface subjected plain strain, a transition from transgranular dimpled fracture to intergranular dimpled fracture is observed during the fracture process.

Effect of stress ratio on fatigue lifetime and crack growth behavior of WC-Co cemented carbide

Two types of fatigue tests, a rotating bending fatigue test and a three- or four-point bending fatigue test, were carried out on a fine grained WC-Co cemented carbide to evaluate its fatigue crack growth behavior and fatigue lifetime. From successive observations of the specimen surface during the fatigue process, it was revealed that most of the fatigue lifetime of the tested WC-Co cemented carbide was occupied with crack growth cycles. Using the basic equation of fracture mechanics, the relationship between the fatigue crack growth rate(da/dN) and the maximum stress intensity factor(Kmax) was derived. From this relation, both the values of the threshold intensity factor(Kth) and the fatigue fracture toughness(Kfc) of the material were determined. The fatigue lifetime of the WC-Co cemented carbide was estimated by analysis based on the modified linear elastic fracture mechanics approach. Good agreement between the estimated and experimental fatigue lifetimes was confirmed.