A review of rock macro-indentation:Theories,experiments,simulations,and applications

Rock macro-indentation plays a fundamental role in mechanical rock breaking for various rock engineering application,such as drilling,tunneling,cutting,and sawing.Over the past decades,extensive research has been conducted to understand the indentation mechanisms and responses through various approaches.This review aims to provide an overview of the current status and recent advancements in theories,experiments,numerical simulations,and applications of macro-indentation in rock engineering.It starts with elaborating on the mechanisms of macro-indentation,followed by a discussion of the merits and limitations of commonly used models.Influence factors and their effects on indentation test results are then summarized.Various numerical simulation methods for rock macro-indentation are highlighted,along with their advantages and disadvantages.Subsequently,the applications of indentation tests and indentation indices in characterizing rock properties are explored.It reveals that compression-tension,compression-shear,and composite models are widely employed in rock macroindentation.While the compression-tension model is straightforward to use,it may overlook the anisotropic properties of rocks.On the other hand,the composite model provides a more comprehensive description of rock indentation but requires complex calculations.Additionally,factors,such as indentation rate,indenter geometry,rock type,specimen size,and confining pressure,can significantly influence the indentation results.Simulation methods for macro-indentation encompass continuous medium,discontinuous medium,and continuous-discontinuous medium methods,with selection based on their differences in principle.Furthermore,rock macro-indentation can be practically applied to mining engineering,tunneling engineering,and petroleum drilling engineering.Indentation indices serve as valuable tools for characterizing rock strength,brittleness,and drillability.This review sheds light on the development of rock macro-indentation and its extensive application in engineering practice.Specialists in the field can gain a comprehensive understanding of the indentation process and its potential in various rock engineering endeavors.

Mechanism and Method of Testing Fracture Toughness and Impact Absorbed Energy of Ductile Metals by Spherical Indentation Tests

To address the problem of conventional approaches for mechanical property determination requiring destructive sampling, which may be unsuitable for in-service structures, the authors proposed a method for determining the quasi-static fracture toughness and impact absorbed energy of ductile metals from spherical indentation tests (SITs). The stress status and damage mechanism of SIT, mode I fracture, Charpy impact tests, and related tests were frst investigated through fnite element (FE) calculations and scanning electron microscopy (SEM) observations, respectively. It was found that the damage mechanism of SITs is diferent from that of mode I fractures, while mode I fractures and Charpy impact tests share the same damage mechanism. Considering the diference between SIT and mode I fractures, uniaxial tension and pure shear were introduced to correlate SIT with mode I fractures. Based on this, the widely used critical indentation energy (CIE) model for fracture toughness determination using SITs was modifed. The quasi-static fracture toughness determined from the modifed CIE model was used to evaluate the impact absorbed energy using the dynamic fracture toughness and energy for crack initiation. The efectiveness of the newly proposed method was verifed through experiments on four types of steels: Q345R, SA508-3, 18MnMoNbR, and S30408.

Experimental investigation on hard rock fragmentation of inserted tooth cutter using a newly designed indentation testing apparatus

This investigation aims to explore the effects of stress conditions and rock cutting rates on hard rock fragmentation through indentation tests on a newly designed triaxial testing apparatus.This apparatus was designed to realize a triaxial loading and indentation test of cylindrical specimens using inserted tooth cutter.The boreability and crushing efficiency of granite rock was investigated by analyzing the change rules of the thrusting force,penetration depth,characteristics of chippings and failure patterns.Several quantitative indexes were used to evaluate rock boreability in this investigation.The granite rock samples all had a chiselled pit and a crushed rock core.Under initial stress conditions,only flat-shape chippings were stripped from the rock surface when the thrusting force reached 20 kN.The rock cutting special energy had a close correlation with the initial stress conditions and inserted tooth shape.Moreover,a thrusting force prediction model was proposed in this paper.The contribution of this study is that for the first time the influence mechanism of the initial triaxial stress conditions on rock fragmentation is investigated using an inserted tooth and the newly designed testing apparatus.This study has a crucial importance for practical underground hard rock crushing in geoengineering.

Determination of reduced Young s modulus of thin films using indentation test

The flat cylindrical indentation tests with different sizes of punch radius were investigated using finite element method （FEM） aimed to reveal the effect of punch size on the indentation behavior of the film/substrate system. Based on the FEM results analysis, two methods was proposed to separate film＇s reduced Young＇s modulus from a film/substrate system. The first method was based on a new weight function that quantifies film＇s and substrate＇s contributions to the overall mechanical properties of the film/substrate system in the flat cylindrical indentation test. The second method, a numerical approach, including fitting and extrapolation procedures was put forward. Both of the results from the two methods showed a reasonable agreement with the one input FE model. At last, the effect of maximum indentation depth and the surface micro-roughness of the thin film on the reduced Young＇s modulus of the film/substrate system were discussed. The methods proposed in the present study provide some new conceptions on evaluating other properties of thin films, e.g. creep, for which a flat-ended punch is also employed.

Interface fracture toughness and fracture mechanisms of thermal barrier coatings investigated by indentation test and acoustic emission technique

Interface fracture toughness and fracture mechanisms of plasma-/sprayed thermal barrier coatings （TBCs） were investigated by interfacial indentation test （ HT） in combination with acoustic emission （ AE ） measurement. Critical load and AE energy were employed to calculate interface fracture toughness. The critical point at which crack appears at the interface was determined by the HT. AE signals produced during total indentation test not only are used to investigate the interface cracking behavior by Fast Fourier Transform （FFT） and wavelet transforms but also supply the mechanical information. The result shows that the AE signals associated with coating plastic deformation during indentation are of a more continuous type with a lower characteristic frequency content （30 -60 kHz） , whereas the instantaneous relaxation associated with interface crack initiation produces burst type AE signals with a characteristic frequency in the range 70 - 200 kHz. The AE signals energy is concentrated on different scales for the coating plastic deformation, interface crack initiation and interface crack propagation. Interface fracture toughness calculated by AE energy was 1. 19 MPam1/2 close to 1.58 MPam1/2 calculated by critical load. It indicates that the acoustic emission energy is suitable to reflect the interface fracture toughness.

New Inverse Method for Determining Uniaxial Flow Properties by Spherical Indentation Test

The spherical indentation test has been successfully applied to inversely derive the tensile properties of small regions in a non-destructive way.Current inverse methods mainly rely on extensive iterative calculations,which yield a considerable computational costs.In this paper,a database method is proposed to determine tensile flow properties from a single indentation force-depth curves to avoid iterative simulations.Firstly,a database that contain numerous indentation force-depth curves is established by inputting varied Ludwic material parameters into the indentation finite elements model.Secondly,for a given experimental indentation curve,a mean square error(MSE)is designated to evaluate the deviation between the experimental curve and each curve in the database.Finally,the true stresses at a series of plastic strain can be acquired by analyzing these deviations.To validate this new method,three different steels,i.e.A508,2.25Cr1 Mo and 316L are selected.Both simulated indentation curves and experimental indentation curves are used as inputs of the database to inversely acquire the flow properties.The result indicates that the pro-posed approach provides impressive accuracy when simulated indentation curves are used,but is less accurate when experimental curves are used.This new method can derive tensile properties in a much higher efficiency compared with traditional inverse method and are therefore more adaptive to engineering application.

Elastic modulus of claystone evaluated by nano-/micro-indentation tests and meso-compression tests

Toarcian claystone such as that of the Callovo-Oxfordian is a qualified multiphase material. The claystone samples tested in this study are composed of four main mineral phases: silicates(clay minerals, quartz,feldspars, micas)(z86%), sulphides(pyrite)(z3%), carbonates(calcite, dolomite)(z10%) and organic kerogen(z1%). Three sets of measurements of the modulus of deformability were compared as determined in(i) nanoindentation tests with a constant indentation depth of 2 mm,(ii) micro-indentation tests with a constant indentation depth of 20 mm, and(iii) meso-compression tests with a constant displacement of 200 mm. These three experimental methods have already been validated in earlier studies. The main objective of this study is to demonstrate the influence of the scaling effect on the modulus of deformability of the material. Different frequency distributions of the modulus of deformability were obtained at the different sample scales:(i) in nano-indentation tests, the distribution was spread between 15 GPa and 90 GPa and contained one peak at34 GPa and another at 51 GPa;(ii) in the micro-indentation tests, the distribution was spread between 25 GPa and 60 GPa and displayed peaks at 26 GPa and 37 GPa; and(iii) in the meso-compression tests, a narrow frequency distribution was obtained, ranging from 25 GPa to 50 GPa and with a maximum at around 35 GPa.

Computer Simulation of the Indentation Creep Tests on Particle-Reinforced Composites

A systematical simulation has been carried out on the indentation creep test on particle-reinforced composites. The deformation, failure mechanisms and life are analyzed by three reasonable models. The following five factors have been considered simultaneously: creep property of the particle, creep property of the matrix, the shape of the particle, the volume fraction of the particle and the size (relative size to the particle) of the indentation indenter. For all the cases, the power law respecting to the applied stress can be used to model the steady indentation creep depth rate of the indenter, and the detail expressions have been presented. The computer simulation precision is analyzed by the two-phase model and the three-phase model. Two places of the stress concentration are found in the composites. One is ahead of the indentation indenter, where the high stress state is deduced by the edge of the indenter and will decrease rapidly near to a steady value with the creep time. The other one is at the interface, where the high stress state is deduced by the misfit of material properties between the particles and matrix. It has been found that the creep dissipation energy density other than a stress parameter can be used to be the criterion to model the debonding of the interfaces. With the criterion of the critical creep dissipation energy density, a power law to the applied stress with negative exponent can be used to model the failure life deduced by the debonding of interfaces. The influences of the shape of the particles and the matching of creep properties of particle and matrix can be discussed for the failure. With a crack model, the further growth of interface crack is analyzed, and some important experimental phenomena can be predicted. The failure mechanism which the particle will be punched into matrix has been also discussed. The critical differences between the creep properties of the particles and matrix have been calculated, after a parameter has been defined. In the view of competition of failure mechanisms, the best matching of the creep properties of the two phases and the best shape of the particles are discussed for the composite design.

DETERMINATION OF CREEP PROPERTIES OF THERMAL BARRIER COATING(TBC)SYSTEMS FROM THE INDENTATION CREEP TESTING WITH ROUND FLAT INDENTERS

Indentation creep behavior with cylindrical flat indenters on the thermal barrier coating (TBC) was studied by finite element method (FEM). On ike constant applied indentation creep stress, there is a steady creep rate for each case studied for different creep properties of the TBC system. The steady creep depth rate depends on the applied indentation creep stress and size of the indenters as well as the creep properties of the bond coat of the TBC and the substrate. The possibilities to determine the creep properties of a thermal barrier system from indention creep testing were discussed. As an example, with two different size indenters, the creep properties of bond coat of the TBC system can be derived by an inverse FEM method. This study not only provides a numerical method to obtain the creep properties of the TBC system, but also extends the application of indentation creep method with cylindrical flat indenters.

Finite element and experimental analysis of Vickers indentation testing on Al_2O_3 with diamond-like carbon coating

Numerical simulation and experimental study of the Vickers indentation testing of the Al2O3 ceramic coated by diamond-like carbon(DLC) layer were conducted.The numerical analysis was implemented by a two-dimensional finite element(FE) axis symmetry model.FE analysis results gave insight into the fracture mechanism of DLC films coated on brittle ceramic(Al2O3) substrates.The maximum principal stress field was used to locate the most expected area for crack formation and propagation during the Vickers indentation testing.The results show that the median crack initiates in the interface under indenter,before ring crack occurs as the indenter presses down.Finally,the plastic deformation appears when the indenter penetrates into the substrate.The thicker DLC coating increases the Vickers hardness and fracture toughness.

Investigation of Adhesion and Fracture Toughness of Thermally Grown Oxide Scales by Interface Indentation Test

The adhesion and the fracture toughness of thermally grown oxide scales for pure nickel were investigated using Vickers indentation technique. The nickel samples were oxidised at 1200°C for 100h-600h. The crack length induced by Vickers indentation test at NiO/Ni interface increases linearly with the incresing of the applied load in a logarithmic scale for each oxide thickness. There is a critical load Pc, when the applied load P>PC, the crack is produced at the oxide/metal interface. The critical load PC decreases with the increasing of the oxide thickness. Therefore, the relation between the critical load PC and the oxide thickness ho may be used as describing the adhesion of of thermally grown oxide scales. For pure nickel, the Pc-ho relation can be represented by the equation Pc = 761439e"°’°695’1" The fracture toughness in oxide and at the interface decrease with the increasing of the oxide thickness in equation K0 —1.02l4Ln(h0) + 7.3382 (in oxide) and KJ = 529.7In,,"**424 (at the interface). And there is a higher fracture toughness at the NiO/Ni interface. Therefore, for pure nickel, the oxide/metal interface is stronger than the oxide.

Numerical Evaluation of Strength in the Interface during Indentation Spherical Testing in Thin Films

The need for more components that are more resistant to wear and corrosion has promoted a growing interest in surface engineering. The search for improved tribological properties in materials contributes to the development of processes that extend the useful life of components and their applications in increasingly severe environments. In this respect, thin ceramic coatings have been used to enhance the tribological properties of components that operate under these conditions. However, new experimental assays are needed to assess the behaviour of these films and their surface as substrate. These experimental analyses require the use of sophisticated equipment and specialized personnel. On the other hand, with advances in computational mechanics, the application of numerical analysis to solve numerous technological problems has been increasingly frequent, owing to its low operational costs. This study aims to simulate an indentation assay with spherical penetrator in systems composed of thin ceramic film deposited on metallic substrate using a Finite Element commercial code. The main objective of this study was to evaluate the field behaviour of stresses in the contact region of the indenter with the sample, on the outline of the impression made by the penetrator and, primarily, on the film-substrate interface.

An inverse problem in film/substrate indentation:extracting both the Young's modulus and thickness of films

In an indentation test,the effective Young's modulus of a film/substrate bilayer heterostructure varies with the indentation depth,a phenomenon known as the substrate effect.In previous studies investigating this,only the Young's modulus of the film was unknown.Once the effective Young's modulus of a film/substrate structure is determined at a given contact depth,the Young's modulus of the film can be uniquely determined,i.e.,there is a one-to-one relation between the Young's modulus of the film and the film/substrate effective Young's modulus.However,at times it is extremely challenging or even impossible to measure the film thickness.Furthermore,the precise definition of the layer/film thickness for a two-dimensional material can be problematic.In the current study,therefore,the thickness of the film and its Young's modulus are treated as two unknowns that must be determined.Unlike the case with one unknown,there are infinite combinations of film thickness and Young's modulus which can yield the same effective Young's modulus for the film/substrate.An inverse problem is formulated and solved to extract the Young's modulus and thickness of the film from the indentation depth-load curve.The accuracy and robustness of the inverse problem-solving method are also demonstrated.

DETERMINATION OF CREEP PARAMETERS FROM INDENTATION CREEP EXPERIMENTS

The possibilities of determining creep parameters for a simple Norton law material are explored from indentation creep testing. Using creep finite element analysis the creep indentation test technique is analyzed in terms of indentation rates at constant loads. Emphasis is placed on the relationships between the steady creep behavior of indentation systems and the creep property of the indented materials. The role of indenter geometry, size effects and macroscopic constraints is explicitly considered on indentation creep experiments. The influence of macroscopic constraints from the material systems becomes important when the size of the indenter is of the same order of magnitude as the size of the testing material. Two methods have been presented to assess the creep property of the indented material from the indentation experimental results on the single-phase-material and two-phase-material systems. The results contribute to a better mechanical understanding and extending the application of indentation creep testing.

Application of Automated Ball Indentation for Property Measurement of Degraded Zr2.5Nb

In this work, Automated Ball Indentation (ABI) technique is based on load controlled multiple indentations (at a single penetration location) of a polished surface by a spherical indenter (0.7 to 1.46 mm) and indentation depth is progressively increased to a maximum user specified limit with intermediate partial unloading. This technique permits measurement of yield strength, stress-strain curve, strength coefficient and strain hardening exponent. ABI Testing was carried out on samples of Zr-Nb2.5 (Pressure Tube Material) with different heat treatment conditions in which temperature was varying (550 degree to 900 degree and retention time was varying 0.5 to 6 hour and furnace cooled. For all these test material and conditions, the ABI derived results were in very good agreement with those from conventional standard test methods.

基于压痕试验的岩石力学参数的卡尔曼滤波反演

压痕试验是间接评估岩体力学特性的重要方法,为了更好地利用压痕试验评估岩体力学参数,本研究采用一种基于扩展卡尔曼滤波算法的参数反演方法。基于室内压痕试验获得的荷载-压入深度曲线数据,通过弹塑性数值仿真模型构建岩体弹塑性参数与压痕曲线的响应关系,进而利用卡尔曼滤波算法实现对岩石弹塑性参数的反演和优化分析。结果表明,本研究方法具有较好的收敛性和较高的识别精度,反演得到的岩石弹性参数均值的相对误差在10%左右,塑性参数的反演结果相对误差小于20%。较传统单一经验公式方法,本研究方法具有更高的预测精度,对多种不同岩性岩体都有较好的适用性。

高温微米球压痕测试装置的设计与应用

为了将“双碳”理念融入实验教学,搭建了高温微米球压痕测试装置。该测试装置包括常温压痕测试模块、加热温控系统、隔热结构3个部分,可实现室温至300℃下的压痕测试。通过温控系统加热升温并保持温度恒定后,多次加卸载循环下获得相应温度的压入载荷-位移曲线,利用计算软件拟合得到应力-应变曲线并计算屈服强度及抗拉强度,实现与常规高温拉伸实验的关联。在对Q345钢块状试样进行室温至300℃下的测试后,获得了相应的屈服强度与抗拉强度,与标准拉伸曲线进行对比,误差均在合理范围内。

基于Berkovich压痕应变能量密度的钢材断裂韧性评价方法

为改善压痕法测试断裂韧性过程中测量标准不同和精度不足的问题,基于临界压痕能量(Critical indentation energy, CIE)法,提出了基于Berkovich压痕应变能量密度(Strain energy density, SED)评估钢材断裂韧性的方法。同时考虑弹性和塑性能量并修正临界总压深,评价了9种钢材的韧性。结果表明,发现仅考虑塑性能量所测量韧性的相对误差在5%~20%,而本文同时考虑弹性和塑性能量所测量韧性的相对误差在5%以内。同时,确定临界总压深的拟合范围需要避开材料近表面弹性模量上升的区域,改善了基于CIE法使用Berkovich压头评估钢材断裂韧性的精确度。

TC17钛合金表面残余应力的点阵式维氏压痕测试

采用点阵式维氏压痕测试方法得到TC17钛合金表面12个测试点的载荷-深度曲线;通过等效材料维氏压痕模型计算合金表面12个测试点的双向残余应力和单向残余应力,将残余应力值代入ANSYS 19.2有限元分析软件中得到载荷-深度曲线,并进行试验验证。结果表明:试验得到表面不同测试点的应力均为残余拉应力;采用有限元方法模拟得到双向残余应力和单向残余应力下的载荷-深度曲线与试验结果吻合较好,载荷-深度曲线的加载曲率的相对误差均小于1.5%,等效材料维氏压痕模型可以准确地预测合金表层单向残余应力和双向残余应力分布。

基于综合加权评分的后防擦条内板注塑参数多目标优化

在Moldflow2019模流分析软件中,对浇口位置进行充分模拟,综合比对后发现,后防擦条内板选择两浇口充填较合适。根据注塑机型号将模具设置为“1模2腔”结构;选用标准热流道,最大限度减少流道凝料,体现绿色设计理念。选取定模水路直径、隔水管直径、熔体温度、注射压力、保压压力、保压时间为研究对象,利用正交试验进行研究,通过综合加权评分对翘曲量及缩痕指数进行加权,得到第15组工艺参数综合评分最高,其值为0.998。当定模水路直径为10 mm、隔水管直径为12 mm、熔体温度为217℃、注射压力为115 MPa、保压压力为85%、保压时间为15 s时,制品的最大翘曲变形量为2.185 mm、总体翘曲率为0.105%~0.210%;缩痕指数为2.823%,与初始参数下的数值相比,减少了48.472%。试验证明了制品成型较好。