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.

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.

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.

An Advanced Control Strategy for Dual-Actuator Driving System in Full-Scale Fatigue Test of Wind Turbine Blades

A new dual-actuator fatigue loading system of wind turbine blades was designed.Compared with the traditional pendulum loading mode,the masses in this system only moved linearly along the loading direction to increase the exciting force.However,the two actuators and the blade constituted a complicated non-linear energy transferring system,which led to the non-synchronization of actuators.On-site test results showed that the virtual spindle synchronous strategy commonly used in synchronous control was undesirable and caused the instability of the blade’s amplitude eventually.A cross-coupled control strategy based on the active disturbance rejection algorithm was proposed.Firstly,a control system model was built according to the synchronization error and tracking error.Furthermore,based on arranging the transition process,estimating the system state and error feedback,and compensating disturbance,an active disturbance rejection controller was designed by adopting the optimal control function.Finally,on-site test results showed that the cross-coupled control strategy based on the active disturbance rejection algorithm could ensure the synchronization of two actuators.The maximum speed synchronization error of the two motors was less than 16 RPM,the displacement synchronization error of the two actuators was less than 0.25 mm and approaching zero after 4 seconds,and the peak value of vibration of the blade was less than 5 mm,which satisfied the fatigue test requirement.

New Fatigue Test and Statistical Method for Metallic Materials Used in Vehicle Transmissions

Aim To improve the efficiency of fatigue material tests and relevant statistical treatment of test data. Methods\ Least square approach and other special treatments were used. Results and Conclusion\ The concepts of each phase in fatigue tests and statistical treatment are clarified. The method proposed leads to three important properties. Reduced number of specimens brings to the advantage of lowering test expenditures. The whole test procedure has more flexibility for there is no need to conduct many tests at the same stress level as in traditional cases.

Fatigue damage evaluation by metal magnetic memory testing

Tension-compression fatigue test was performed on 0.45% C steel specimens.Normal and tangential components of magnetic memory testing signals,Hp(y) and Hp(x) signals,with their characteristics,K of Hp(y) and Hp(x)M of Hp(x),throughout the fatigue process were presented and analyzed.Abnormal peaks of Hp(y) and peak of Hp(x) reversed after loading; Hp(y) curves rotated clockwise and Hp(x) curves elevated significantly with the increase of fatigue cycle number at the first a few fatigue cycles,both Hp(y) and Hp(x) curves were stable after that,the amplitude of abnormal peaks of Hp(y) and peak value of Hp(x) increased more quickly after fatigue crack initiation.Abnormal peaks of Hp(y) and peak of Hp(x) at the notch reversed again after failure.The characteristics were found to exhibit consistent tendency in the whole fatigue life and behave differently in different stages of fatigue.In initial and crack developing stages,the characteristics increased significantly due to dislocations increase and crack propagation,respectively.In stable stage,the characteristics remained constant as a result of dislocation blocking,K value ranged from 20 to 30 A/(m·mm)-1,and Hp(x)M ranged from 270 to 300 A/m under the test parameters in this work.After failure,both abnormal peaks of Hp(y) and peak of Hp(x) reversed,K value was 133 A/(m·mm)-1 and Hp(x)M was-640 A/m.The results indicate that the characteristics of Hp(y) and Hp(x) signals were related to the accumulation of fatigue,so it is feasible and applicable to monitor fatigue damage of ferromagnetic components using metal magnetic memory testing(MMMT).

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.

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.

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.

Multi-Excitation Fatigue Testing for Large Full-Scale Wind Turbine Blade

In order to solve the problem of insufficient exciting force of equipment for large full-scale wind turbine blade fatigue testing,the influence of gravity on the performance of excitation equipment and fatigue damage evaluation of the different positions of wind turbine blades are analyzed.With the multi-excitation loading in the horizontal direction,the actuator force of the excitation equipment does not need to overcome the gravity of the dynamic mass,which directly outputs the exciting force of the system vibration.The excitation efficiency of the equipment is 77%higher than that of the vertical load.The gravity moment of the horizontal loading mode is perpendicular to the loading direction.That is,the mean load in the flapwise direction is zero.The weight of excitation equipment could replace the tuning mass on the condition that the self-weight of equipment is reduced by the multi-excitation mode,which helps the excitation equipment play the comprehensive function of excitation equipment and tuning mass.At the same time,the gravity moment in the edgewise direction will be decreased by 17.0%22.5%under the multi-excitation horizontal loading mode.In the vertical loading mode,the gravity moment is the mean load,which only increases fatigue damage accumulation by 15.6%.By comparing the role of gravity in the excitation equipment and fatigue damage evaluation,the multi-excitation horizontal loading mode has more advantage to performance the exciting force than the contribution of gravity to the fatigue damage accumulation in the vertical loading mode.Through the fatigue testing of multi-excitation horizontal loading,the potential of excitation equipment is explored,and the problem of insufficient exciting force in large full-scale wind turbine blade fatigue testing will be solved.

RESEARCH ON SONIC FATIGUE CALCULATION AND TEST FOR AIRCRAFT PANEL

The sonic fatigue life of the aluminium rectangular panel was calculated using the concise method[1], and the sonic fatigue test was conducted on progressive wave tube (PWT) test facility. A comparison was made between the results of calculation and test, and it shows reasonable agreement between these two results.

Acoustic Emission Properties of Concrete Slab During Fatigue Testing with a Running-Wheel Load

AE （acoustic emission） signals from concrete slab during fatigue testing with a running-wheel load were evaluated. The signals were recorded by remote sensors connected to a computer network. The sensing equipment consisted of 60 kHz resonant-type AE sensors mounted on a reinforcing steel bar as a waveguide, together with a 16-channel sensor highway AE system. Because the detected AE signals included periodic mechanical noise from the motion of the wheel, these noises were eliminated by means of signal processing. The AE waveguide measurement over a length of 3 m detected fractures as vertical and horizontal cracks in the RC （reinforced concrete） slab. Those cracks were analyzed by correlating AE parameters with macroscopic distortions and the numbers of fatigue cycles. In the AE events and AE energy, two types of AE phenomena, active region and inactive region, were observed during fatigue testing. The vertical cracks were characterized by an AE amplitude of 58 dB, a peak frequency of 30 kHz, and a ratio of the rise time to the maximum amplitude value （RA） of 100. The horizontal cracks were characterized by an AE amplitude of 85 dB, a peak frequency of 60 kHz, and an RA value of 10.

Estimation of Fatigue Strength of Reinforced Complete Upper Denture Using a Newly Designed Testing Machine: A Laboratory Research Project

In the present study, an aero pneumatic fatigue testing machine for complete dentures was designed, fabricated, and tested for the evaluation of the fatigue life of reinforced complete upper denture (CUD). On completion and testing, it was observed that the machine has the potential of generating reliable number of cyclic data. The machine’s performance was evaluated using test specimens of identical CUDs that were machined in conformity with standard procedures. The fatigue machine compressed the lower dental arch over the upper denture-specimen in centric occlusion, in the same way that the two masticatory muscles pull the lower jaw over the upper jaw during chewing. The incorporation of glass fibres into the CUD using a sandwich technique quadruples the lifespan of the denture (P = 0.004). The low standard deviation, along with the low coefficient of variation (CV) of the group of unreinforced dentures shows the repeatability of the results and the reliability of the machine. The high standard deviation and coefficient of variation of reinforced dentures was expected, since a high variation of results is usually recorded in fibre reinforcement cases. This research confirmed the view that the crack during denture fracture initiates in the anterior palatal area and propagates to the posterior.

Numerical study of fatigue damage of asphalt concrete using cohesive zone model

In order to investigate the fatigue behavior of asphalt concrete, a new numerical approach based on a bi-linear cohesive zone model （CZM） is developed. Integrated with the CZM, a fatigue damage evolution model is established to indicate the gradual degradation of cohesive properties of asphalt concrete under cyclic loading. Then the model is implemented in the finite element software ABAQUS through a user-defined subroutine. Based on the proposed model, an indirect tensile fatigue test is finally simulated. The fatigue lives obtained through numerical analysis show good agreement with laboratory results. Fatigue damage accumulates in a nonlinear manner during the cyclic loading process and damage initiation phase is the major part of fatigue failure. As the stress ratio increases, the time of the steady damage growth stage decreases significantly. It is found that the proposed fatigue damage evolution model can serve as an accurate and efficient tool for the prediction of fatigue damage of asphalt concrete.

Fatigue behavior of crane beam strengthened with CFRP

In order to study the fatigue behavior of the damaged reinforced concrete （RC） beams strengthened by carbon fiber reinforced polymer （CFRP） laminate, three T-shaped beams strengthened by CFRP and one contrasting beam are tested under fatigue loading, with the parameters of different modes of strengthening and different fatigue load levels considered. The main results obtained from the tests are： the width of the crack decreases 50. 2% to 66%, and the development of the crack is limited; the stress of steel decreases 24. 1% to 28. 2%, and the stiffness increases 14.9% to 16. 1% after being strengthened. Based on the technical specification for strengthening concrete structures with CFRP and the conclusions from the tests, a calculating scheme of the flexure stiffness is given, which can be used for reference in engineering design. Finally, some suggestions are given for design in fatigue strengthening.

GIGACYCLE FATIGUE BEHAVIOR OF CAST ALUMINUM IN TENSION AND TORSION LOADING

An improved understanding of fatigue behavior of a cast aluminum alloy（2-AS5U3G-Y35）in very high cycle regime is developed through the ultrasonic fatigue test in axial and torsion loading.The new developed torsion fatigue system is presented.The effects of loading condition and frequency on the very high cycle fatigue（VHCF）are investigated.The cyclic loading in axial and torsion at 35 Hz and 20 kHz with stress ratio R=-1 is used respectively to demonstrate the effect of loading condition.S-N curves show that the fatigue failure occurs in the range of 105—1010 cycles in axial or torsion loading and the asymptote of S-N curve is inclined,but no fatigue limit exists under the torsion and axial loading condition.The fatigue fracture surface shows that the fatigue crack initiates from the specimen surface subjected to the cyclic torsion loading.It is different from the fatigue fracture characteristic in axial loading in which fatigue crack initiates from subsurface defect in very high cycle regime.The fatigue initiation is on the maximum shear plane,the overall crack orientation is on a typical spiral 45° to the fracture plane and it is the maximum principle stress plane.The clear shear strip in the torsion fatigue fracture surface shows that the torsion fracture is the shear fracture.

FATIGUE LIFE PREDICTION METHOD FOR IMPACTED LAMINATES

The existing models are established based on the fatigue behavior of impacted laminates.It makes them unsuitable for the general use.So,a general 3-D progressive damage fatigue life prediction method for impacted laminates is developed based on the progressive damage theory and the fatigue behavior of unimpacted unidirectional plies.The model can predict the fatigue life of laminated composites with different ply parameters,geometry,impact damage,and fatigue loading conditions.In order to obtain the impact damage information in the case that no impact test data is available,a whole damage process analysis method for laminated composites under the impact loading and the fatigue loading is analyzed.The predicted damage statuses of composite laminates can be used to analyze the post-impact fatigue life.A parametric modeling program is developed to predict the impact damage process and the fatigue life of impacted laminates based on the whole damage process analysis method.The most relative error between the prediction and the test results is 7.78%.

Evaluation of fatigue property of asphalt mixtures based on digital image correlation method

In order to evaluate the accumulative of tensile strain in the process of fatigue failure, the digital image correlation（DIC） method was utilized to characterize the tensile strain development of asphalt mixtures in the indirect tensile（IDT）fatigue test. Three typical hot mix asphalt（HMA） mixtures with varying nominal maximum aggregate sizes were tested at four stress levels. During the tests, a digital camera was mounted to capture the displacement/strain fields on the surface of the specimen by recording the real-time change of speckle position. The results indicate that the vertical deformation curve can barely evaluate the fatigue performance accurately due to the non-negligible local deflection near the loading point. However, based on the analysis of strain fields,the optimal fatigue cracking zone is determined as a 40mm×40mm rectangle in the middle of the specimens. Also, a reasonable fatigue model based on the tensile strain curves calculated by DIC is proposed to predict the fatigue lives of asphalt mixtures.

Experimental investigation on fatigue of blade specimen subjected to resonance and effect of a damping hard coating treatment

Failures due to high-cycle fatigue have led to a high cost in aerospace engineering over the past few decades.In this paper,the experimental results of the fatigue behavior of compressor blade specimen subjected to resonance and the effects of a damping hard coating on relieving the fatigue progress are presented.The crack initiation and propagation processes were observed under resonance of the first bending mode by using the resonant frequencies as the indicator.Significant nonlinear features were observed in the spectrum of the blade with a fatigue crack.The finite element model considering the breathing crack was established with nonlinear contact based on the crack localization and size,which was obtained by ultrasonic phased array technology.The simulation results of the vibration behavior of the cracked blade were obtained and consistent with the experimental results.A NiCrAlY coating was deposited on the blade,and increases in the fatigue life were observed under the same condition.The results of this paper can help to better understand the fatigue of a compressor blade subjected to resonance and provide a preference for the application of a damping hard coating on compressor blades.

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.