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Keywords: lightweight design, car body manufacturing, body-in-white, aluminum alloys, magnesium alloys, riv-bonding, adhesive, self-piercing riveting, SPR, static strength, fatigue performance
Published in DKUM: 02.04.2024; Views: 489; Downloads: 348
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Abstract: The proposed research presents the comprehensive investigation of the Low Cycle Fatigue (LCF) behaviour of two high-strength aluminium alloys of series AA 6xxx: the conventional alloy AA 6110A and the newly developed alloy AA 6086. Both alloys were characterised in the as-cast condition after homogenisation, extrusion, and T6 heat treatment. The quasi-static strength and hardness of the aluminium alloy AA 6086 were found to be significantly higher if compared to the AA 6110A alloys, while the ductility was a little bit smaller. The LCF tests showed that the AA 6086 alloy is more suitable for the high-cycle fatigue regime. On the other hand, the engineering advantage of the AA 6110A alloy is only for low-cycle fatigue applications if less than 100 loading cycles are expected in the service life of the analysed structure. The fatigue cracks formed predominantly on the α-AlMnSi intermetallic particles in both alloys, and, during LCF tests, exhibited small crack propagation. The area of the fatigue crack growth was much smaller than the area of the forced fracture. At smaller amplitude strains the fatigue striations were present at the fracture surface, while, at higher amplitude strains, they were not present. The obtained experimental results represent a good basis for engineering design applications of the analysed alloys AA 6086 and AA 6110A.
Keywords: aluminijeve zlitine, malociklično utrujanje, eksperimentalno testiranje, fraktografija, aluminium alloys, low cycle fatigue, experimental testing, fractography
Published in DKUM: 29.03.2024; Views: 197; Downloads: 13
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Abstract: This study analyzed the fatigue failure of a parabolic spring made of 51CrV4 steel. A fracture mechanics approach was used to quantify the driving force and resistance for different loading configurations, inclusion sizes, and residual stresses. The analysis considered surface and internal initiation processes, including the impact of residual stresses introduced by shot peening. Key findings include the ability of the methodology to analyze the variables influencing fatigue resistance and failure configuration, the competition between surface and internal fracture processes, the limitation of residual stresses, the importance of minimizing the maximum inclusion size, and the potential for enhancing the propagation threshold for long cracks. The employed methodology facilitates not only the quantification but also the comprehension of the influence of the intrinsic material resistance on the fracture process.
Keywords: spring, fracture mechanics, short cracks, fatigue strenght estimation, small defect assessment
Published in DKUM: 26.03.2024; Views: 189; Downloads: 22
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Abstract: Porosity in sintered materials negatively affects its fatigue properties. In investigating its influence, the application of numerical simulations reduces experimental testing, but they are computationally very expensive. In this work, the application of a relatively simple numerical phase-field (PF) model for fatigue fracture is proposed for estimation of the fatigue life of sintered steels by analysis of microcrack evolution. A model for brittle fracture and a new cycle skipping algorithm are used to reduce computational costs. A multiphase sintered steel, consisting of bainite and ferrite, is examined. Detailed finite element models of the microstructure are generated from high-resolution metallography images. Microstructural elastic material parameters are obtained using instrumented indentation, while fracture model parameters are estimated from experimental S–N curves. Numerical results obtained for monotonous and fatigue fracture are compared with data from experimental measurements. The proposed methodology is able to capture some important fracture phenomena in the considered material, such as the initiation of the first damage in the microstructure, the forming of larger cracks at the macroscopic level, and the total life in a high cycle fatigue regime. However, due to the adopted simplifications, the model is not suitable for predicting accurate and realistic crack patterns of microcracks.
Keywords: sintered steel, microcracks, fatigue, phase-field method, porosity
Published in DKUM: 09.02.2024; Views: 349; Downloads: 22
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Abstract: The study focuses on the behavior of the AA7075-T6 material, widely used in the aerospace industry, under dynamic loadings. The material undergoes processing, including cold rolling and stretching, resulting in residual stress compressive stresses on its surface. The research centers on monitoring changes in the surface condition during dynamic loaidngs using Fiber Bragg Grating (FBG) sensors and numerical simulations. The dissertation includes experimental testing of AA 7075-T6 material samples, numerical simulations of optical fiber responses to tensile loads, and an investigation of surface condition changes using techniques such as focused ion beam engraving and scanning electron microscope observation. The study has shown that the surface condition of the material changes even under low dynamic loads, including variations in surface roughness, residual stresses, and FBG response. Despite low load levels, changes in FBG sensor spectra are observable. The dissertation concludes that the surface condition of the material changes during dynamic loadings, detectable through FBG sensors. It underscores the effectiveness of FBG sensors in monitoring stress levels throughout the material’s service life, particularly on the side lobes of the spectral response. In summary, the research on the dynamic behavior of the AA7075-T6 alloy offers valuable insight into surface condition changes that can impact the integrity and durability of materials in the aerospace industry.
Keywords: fatigue, high cycle load, Fiber Bragg grating
Published in DKUM: 05.01.2024; Views: 466; Downloads: 56
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