1. Structural integrity and life assessment of Ti-6Al-4V orthopaedic implantsKatarina Čolić, Svetlana M. Kostić, Simon Sedmak, Nenad Gubeljak, Aleksandar Grbović, 2024, izvirni znanstveni članek Opis: This paper presents an experimental and numerical analysis of the mechanical behaviour of orthopaedic implants with crack-type defects, considering the principles and advantages of the modern X-FEM method, which was used due to limitations of traditional FEM in terms of crack growth simulation, especially for complex geometries. In X-FEM, the finite element space is enriched with discontinuity functions and asymptotic functions at the crack tip, which are integrated into the standard finite element approximation using the unity division property. Though rare, femoral component failures are well-documented complications that can occur after hip prosthetic implantation. Most stem fractures happen in the first third of the implant due to the loosening of the proximal stem and fixation of the distal stem, leading to bending and eventual fatigue failure. The main goal of this paper was to obtain accurate and representative models of such failures. Experimental analyses of the mechanical behaviour of implants subjected to physiological loads, according to relevant standards, using a new combined approach, including both experiments and numerical simulations was presented. The goal was to verify the numerical results and obtain a novel, effective methodology for assessing the remaining fatigue life of hip implants. For this purpose, the analysis of the influence of Paris coefficients on the total number of cycles was also considered. Hence, this simulation involved defining loads to closely mimic real-life scenarios, including a combination of activities such as ascending stairs, stumbling, and descending stairs. The tensile properties of the titanium alloy were experimentally determined, along with the Paris law coefficients C and m. The finite element software ANSYS 2022R2 version was used to develop and calculate the three-dimensional model with a crack, and the resulting stresses, stress intensity factors, and the number of cycles presented in the figures, tables, and diagrams. The results for the fatigue life of a partial hip implant subjected to various load cases indicated significant differences in behaviour, and this underscores the importance of analysing each case individually, as these loads are heavily influenced by each patient’s specific activities. It was concluded that the use of numerical methods enabled the preliminary analyses of the mechanical behaviour of implants under fatigue loading for several different load cases, and these findings can be effectively used to predict the possibility of Ti-6Al-4V implant failure under variable cyclic loads. Ključne besede: structural integrity, fatigue fracture, extended finite element method (XFEM), experimental testing, DIC, numerical simulations, stress intensity factor, orthopaedic implants, crack-type defect Objavljeno v DKUM: 21.03.2025; Ogledov: 0; Prenosov: 7
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2. Estimate of the driving force for creep crack growthOtmar Kolednik, Marko Kegl, Nenad Gubeljak, Jožef Predan, 2025, izvirni znanstveni članek Opis: A discussion on the conventional creep crack growth parameters, e.g. the experimental C*-integral, C*exp, or the experimental Ct-integral, Ct,ssc, shows that the physical meaning of these parameters for growing cracks in elastic–plastic, creeping materials is not fully clear. Therefore, a comparison is presented in this paper between the conventional creep crack growth parameters, several J-integral related parameters and the crack driving force (CDF), which has been used in linear elastic and elastic–plastic fracture mechanics. The CDF for elastic–plastic, creeping materials is derived from basic thermodynamic principles and by applying the concept of configurational forces (CFs). A comprehensive numerical study is performed where crack propagation is modelled by alternating creep and crack extension steps at constant loads in a compact tension specimen made of the nickel-base superalloy Waspaloy at a temperature of 700 °C. The CDF is evaluated by a CF-based post-processing procedure after a conventional finite element computation. This procedure is applicable for small-scale creep (ssc-), transition creep (tc-) and “moderate” extensive creep (ec-) conditions. For more pronounced ec-conditions, the procedure might have to be adapted. It is shown that C*exp and Ct,ssc reflect the time derivative of the CDF during the creep stages. In contrast, the variations of the CDF coincide well with that of J-values estimated from the crack-tip opening displacement. Ključne besede: fracture mechanics, creep crack growth, crack driving force, C*-integral, J-integral, configurational force concept, finite element method Objavljeno v DKUM: 20.03.2025; Ogledov: 0; Prenosov: 5
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3. Total Knee replacement with an uncemented porous tantalum tibia component: A failure analysisSamo K. Fokter, Nenad Gubeljak, Esther Punzón Quijorna, Primož Pelicon, Mitja Kelemen, Primož Vavpetič, Jožef Predan, Luka Ferlič, Igor Novak, 2022, izvirni znanstveni članek Opis: Porous tantalum has been extensively used in orthopaedic surgery, including uncemented
total knee arthroplasty (TKA). Favourable results were reported with earlier monobloc tibial components and the design evolved to modular implants. We aimed to analyse possible causes for extensive
medial tibia bone loss, resulting in modular porous tantalum tibia baseplate fracture after primary
TKA. Retrieved tissue samples were scanned with 3 MeV focused proton beam for Proton-Induced
X-ray Emission (micro-PIXE) elemental analysis. Fractographic and microstructural analysis were
performed by stereomicroscopy. A full 3D finite-element model was made for numerical analysis
of stress–strain conditions of the tibial baseplate. Histological examination of tissue underneath
the broken part of the tibial baseplate revealed dark-stained metal debris, which was confirmed by
micro-PIXE to consist of tantalum and titanium. Fractographic analysis and tensile testing showed
that the failure of the tibial baseplate fulfilled the criteria of a typical fatigue fracture. Microstructural
analysis of the contact surface revealed signs of bone ingrowth in 22.5% of the surface only and
was even less pronounced in the medial half of the tibial baseplate. Further studies are needed to
confirm the responsibility of metal debris for an increased bone absorption leading to catastrophic
tibial tray failure. Ključne besede: total knee arthroplasty, uncemented, cementless, trabecular metal, porous tantalum, tibial component, cementless baseplate fracture Objavljeno v DKUM: 20.03.2025; Ogledov: 0; Prenosov: 2
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4. Effects of fixture configurations and weld strength mismatch on J-integral calculation procedure for SE(B) specimensPrimož Štefane, Stijn Hertelé, Sameera Naib, Wim de Waele, Nenad Gubeljak, 2022, izvirni znanstveni članek Opis: This work presents the development of a J-integral estimation procedure for deep and
shallow cracked bend specimens based upon plastic ηpl factors for a butt weld made in an S690 QL
high strength low alloyed steel. Experimental procedures include the characterization of average
material properties by tensile testing and evaluation of base and weld metal resistance to stable tearing
by fracture testing of square SE(B) specimens containing a weld centerline notch. J-integral has been
estimated from plastic work using a single specimen approach and the normalization data reduction
technique. A comprehensive parametric finite element study has been conducted to calibrate plastic
factor ηpl and geometry factor λ for various fixture and weld configurations, while a corresponding
plastic factor γpl was computed on the basis of the former two. The modified ηpl and γpl factors were
then incorporated in the J computation procedure given by the ASTM E1820 standard, for evaluation
of the plastic component of J and its corresponding correction due to crack growth, respectively. Two
kinds of J-R curves were computed on the basis of modified and standard ηpl and γpl factors, where
the latter are given by ASTM E1820. A comparison of produced J-R curves for the base material
revealed that variations in specimen fixtures can lead to ≈10% overestimation of computed fracture
toughness JIc. Furthermore, a comparison of J-R curves for overmatched single-material idealized
welds revealed that the application of standard ηpl and γpl factors can lead to the overestimation of
computed fracture toughness JIc by more than 10%. Similar observations are made for undermatched
single material idealized welds, where fracture toughness JIc is overestimated by ≈5%. Ključne besede: metal weld, strength mismatch, fracture, plastic correction factors, fixture rollers, J-R resistance curve Objavljeno v DKUM: 20.03.2025; Ogledov: 0; Prenosov: 2
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5. Experimental characterization and phase-field damage modeling of ductile fracture in AISI 316lVladimir Dunić, Nenad Gubeljak, Miroslav Živković, Vladimir Milovanović, Darko Jagarinec, Nenad Djordjevic, 2024, izvirni znanstveni članek Opis: ) Modeling and characterization of ductile fracture in metals is still a challenging task in
the field of computational mechanics. Experimental testing offers specific responses in the form of
crack-mouth (CMOD) and crack-tip (CTOD) opening displacement related to applied force or crack
growth. The main aim of this paper is to develop a phase-field-based Finite Element Method (FEM)
implementation for modeling of ductile fracture in stainless steel. (2) A Phase-Field Damage Model
(PFDM) was coupled with von Mises plasticity and a work-densities-based criterion was employed,
with a threshold to propose a new relationship between critical fracture energy and critical total
strain value. In addition, the threshold value of potential internal energy—which controls damage
evolution—is defined from the critical fracture energy. (3) The material properties of AISI 316L steel
are determined by a uniaxial tensile test and the Compact Tension (CT) specimen crack growth test.
The PFDM model is validated against the experimental results obtained in the fracture toughness
characterization test, with the simulation results being within 8% of the experimental measurements. Ključne besede: phase-field damage modeling, ductile fracture, crack-tip opening displacement, crack growth, resistance curve, finite element method, simulations Objavljeno v DKUM: 19.09.2024; Ogledov: 0; Prenosov: 9
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6. Comparison of the mechanical properties of hardfacings made by standard coated stick electrodes and a newly developed rectangular stick electrodeEdvard Bjelajac, Andrej Skumavc, Gorazd Lojen, Mirza Manjgo, Tomaž Vuherer, 2024, izvirni znanstveni članek Opis: Cladding with a stick electrode is one of the oldest arc processes for adding a deposit on a base material. The process is suitable for outdoor working, but the disadvantages are low productivity and large dilution rates. In this work, a simple solution is proposed, which would enable cladding of a larger area with one pass and decrease the dilution rate at the same time—a new type of electrode was developed, exhibiting a rectangular cross-section instead of a round one. Hardfacings, welded with E Fe8 electrodes according to EN 14 700 Standard were welded on mild steel S355 J2 base material with three different coated stick electrodes. The first one was a commercially available, standard, round hardfacing electrode, the second was the same, but with a thinner coating, and the third one was a newly developed rectangular electrode. All three types had equal cross-sections of the metallic core and the same type of coating. Manufacturing of the rectangular electrodes in the laboratory is explained briefly. One- and multi-layer deposits were welded with all three types. Differences were observed in the arc behavior between the round and rectangular electrodes. With the rectangular electrode, the microstructure of the deposit was finer, penetration was shallower, and dilution rates were lower, while the hardness was higher, residual stresses predominantly compressive, and the results of instrumented Charpy impact tests and fracture mechanics tests were better. Ključne besede: hardfacing, dilution rate, hardness, Charpy impact toughness, residual stress, fracture toughness Objavljeno v DKUM: 14.05.2024; Ogledov: 298; Prenosov: 26
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8. Fracture mechanics analysis of a fatigue failure of a parabolic springMirco Daniel Chapetti, Bojan Senčič, Nenad Gubeljak, 2023, izvirni znanstveni članek Opis: 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. Ključne besede: spring, fracture mechanics, short cracks, fatigue strenght estimation, small defect assessment Objavljeno v DKUM: 26.03.2024; Ogledov: 189; Prenosov: 24
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9. Evaluation of the impact and fracture toughness of a nanostructured bainitic steel with low retained austenite contentMihael Brunčko, Peter Kirbiš, Ivan Anžel, Leo Gusel, Darja Feizpour, Tomaž Irgolič, Tomaž Vuherer, 2023, izvirni znanstveni članek Opis: The impact and fracture toughness of a nanostructured, kinetically activated bainitic steel was determined using Standard methods. Prior to testing, the steel was quenched in oil and aged naturally for a period of 10 days in order to obtain a fully bainitic microstructure with a retained austenite content below 1%, resulting in a high hardness of 62HRC. The high hardness originated from the very fine microstructure of bainitic ferrite plates formed at low temperatures. It was determined that the impact toughness of the steel in the fully aged condition improved remarkably, whereas the fracture toughness was in line with expectations based on the extrapolated data available in the literature. This suggests that a very fine microstructure is most beneficial to rapid loading conditions, whereas material flaws such as coarse nitrides and non-metallic inclusions are the major limitation for obtaining a high fracture toughness. Ključne besede: evaluation of fracture toughness, impact toughness, nanostructured bainite, natural aging, low retained austenite content, kinetically activated bainite KAB Objavljeno v DKUM: 16.02.2024; Ogledov: 390; Prenosov: 29
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10. Fracture toughness of HSLA welds made on penstock materialZdravko Praunseis, 2019, izvirni znanstveni članek Opis: The presence of different microstructures along the pre-crack fatigue front has a significant effect on the critical crack tip opening displacement (CTOD). This value is the relevant parameter for the safe servicing of welded structures (penstocks). In the case of specimens with the through-thickness notch partly in the weld metal, partly in the heat-affected zone, and partly in the base material, i.e., using the composite notched specimen, the fracture behaviour significantly depends on the portion of the ductile base material, the size, and the distribution of mismatching factor along the vicinity of the crack front. Ključne besede: High Strength low Alloyed Steel, CTOD Fracture Toughness Testing, CTOD-R resistance Curve, Welded joints Objavljeno v DKUM: 22.12.2023; Ogledov: 614; Prenosov: 7
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