scholarly journals Ultrasonic fatigue testing under multiaxial loading conditions on a railway wheel

2019 ◽  
Vol 300 ◽  
pp. 18003 ◽  
Author(s):  
Pedro R. da Costa ◽  
Henrique Soares ◽  
Luís Reis ◽  
Manuel Freitas
Keyword(s):  
Stress Ratio ◽  
Fatigue Testing ◽  
Fatigue Tests ◽  
Cycle Frequency ◽  
Railway Wheel ◽  
Material Specimen ◽  
Hydraulic Machines ◽  
Wide Range ◽  
Ultrasonic Fatigue ◽  
Very High

Ultrasonic fatigue testing is a relative recent fatigue methodology that uses resonant principles for the induction of stress cycles in a specific designed material specimen. This experimental method can apply very high cycle frequency, the most common frequency being 20 kHz, and was created with the main purpose of studying material fatigue life in the Very High Cycle Fatigue regime between 107 and 109 cycles with a higher performance of time and energy wise in comparison to conventional servo-hydraulic machines. In this study an improvement of an already built multiaxial ultrasonic fatigue machine in the Instituto Superior Técnico laboratories was carried out to specific designed specimens and afterwards a fatigue study was made for a material of a worn-out railway wheel. The particular design of the specimen was achieved by numerical and experimental analysis based on previous experiments and components. Thermographic imaging and the application of rosette strain gauges to the main throat of the specimens were conducted in order to validate the improved specimen design and to understand the real induced stresses on the specimen. Afterwards fatigue tests were conducted for several specimens for a wide range of stresses with a stress ratio R=-1 and an axial vs shear stress ratio of around 0.58. Results were analysed and fracture analysis was also carried out.

scholarly journals Ultrasonic fatigue experiments with biaxial cruciform specimens

2019 ◽  
Vol 300 ◽  
pp. 18004
Author(s):  
Pedro R. da Costa ◽  
Diogo Montalvão ◽  
Manuel Freitas ◽  
Luis Reis
Keyword(s):  
Fatigue Testing ◽  
Complex Loading ◽  
Fatigue Tests ◽  
Dynamic Loads ◽  
Structural Components ◽  
Ultrasonic Fatigue ◽  
Innovative Materials ◽  
Wide Energy ◽  
Intended Behaviour ◽  
Very High

Fatigue studies of materials in simple or complex loading systems for any given lifetime is object of continuous research. This is due to the advancements on mechanical and structural components, as well as for new and innovative materials, which implies the knowledge of a materials response to all dynamic loads. The fatigue failure regime beyond what was once considered to be the fatigue limit (infinite life) is characterized between 107 and 109, known as Very High Cycle Fatigue regime. Due to the time consuming and wide energy consumption of conventional fatigue testing for such regime, fatigue tests under ultrasonic actuators are being used, capable of applying the dynamic loads at around 20 kHz. Nowadays, several variants of ultrasonic fatigue tests were already proposed and tested but it is still a somewhat limited fatigue test if compared to the conventional servo-hydraulic fatigue testing machines of general use. In this study, biaxial in plane stresses are induced in specially designed cruciform specimens with ultrasonic fatigue testing resonant principals. Two geometries were numerically analysed, manufactured and experimentally tested, the in-phase tension-tension (T-T) specimen and the out-of-phase compression-tension (C-T) specimen. All specific designed geometries go under a thorough numerical and several experiments analysis for their validation. The specimens showing a correct and as intended behaviour are led to failure.

scholarly journals Fatigue life assessment of a railway wheel material under HCF and VHCF conditions

2018 ◽  
Vol 165 ◽  
pp. 09003 ◽  
Author(s):  
H. Soares ◽  
P. Costa ◽  
M. Freitas ◽  
L. Reis
Keyword(s):  
Stress Ratio ◽  
Life Assessment ◽  
Fatigue Properties ◽  
Railway Wheel ◽  
Initial Application ◽  
Fatigue Life Assessment ◽  
Very High Cycle Fatigue ◽  
Ultrasonic Fatigue ◽  
Wheel Material ◽  
Very High

Fatigue damage and life assessment is still an issue and a challenge nowadays. Many different tests can be performed for the assessment of fatigue properties of any given material. In the present study a worn out railway wheel goes under uniaxial fatigue analyses for the high cycle and very high cycle fatigue regimes through the use of a conventional hydraulic machine and an ultrasonic fatigue test, both with a stress ratio of R=-1. For every used specimen, a life cycle is obtained for the corresponding induced specimen and the data is afterwards plotted. All the fracture surfaces of all failed specimens were analysed. The study and initial application of multiaxial ultrasonic fatigue condition and the design of the corresponding specimen for evaluating the wheel material is also presented.

scholarly journals Review of Multiaxial Testing for Very High Cycle Fatigue: From ‘Conventional’ to Ultrasonic Machines

Machines ◽  
2020 ◽  
Vol 8 (2) ◽  
pp. 25
Author(s):  
Pedro Costa ◽  
Richard Nwawe ◽  
Henrique Soares ◽  
Luís Reis ◽  
Manuel Freitas ◽  
...  
Keyword(s):  
High Cycle Fatigue ◽  
Fatigue Testing ◽  
Fatigue Tests ◽  
Multiaxial Fatigue ◽  
Cycle Fatigue ◽  
New Materials ◽  
Multiaxial Testing ◽  
Very High Cycle Fatigue ◽  
Ultrasonic Fatigue ◽  
Very High

Fatigue is one of the main causes for in service failure of mechanical components and structures. With the development of new materials, such as high strength aluminium or titanium alloys with different microstructures from steels, materials no longer have a fatigue limit in the classical sense, where it was accepted that they would have ‘infinite life’ from 10 million (107) cycles. The emergence of new materials used in critical mechanical parts, including parts obtained from metal additive manufacturing (AM), the need for weight reduction and the ambition to travel greater distances in shorter periods of time, have brought many challenges to design engineers, since they demand predictability of material properties and that they are readily available. Most fatigue testing today still uses uniaxial loads. However, it is generally recognised that multiaxial stresses occur in many full-scale structures, being rare the occurrence of pure uniaxial stress states. By combining both Ultrasonic Fatigue Testing with multiaxial testing through Single-Input-Multiple-Output Modal Analysis, the high costs of both equipment and time to conduct experiments have seen a massive improvement. It is presently possible to test materials under multiaxial loading conditions and for a very high number of cycles in a fraction of the time compared to non-ultrasonic fatigue testing methods (days compared to months or years). This work presents the current status of ultrasonic fatigue testing machines working at a frequency of 20 kHz to date, with emphasis on multiaxial fatigue and very high cycle fatigue. Special attention will be put into the performance of multiaxial fatigue tests of classical cylindrical specimens under tension/torsion and flat cruciform specimens under in-plane bi-axial testing using low cost piezoelectric transducers. Together with the description of the testing machines and associated instrumentation, some experimental results of fatigue tests are presented in order to demonstrate how ultrasonic fatigue testing can be used to determine the behaviour of a steel alloy from a railway wheel at very high cycle fatigue regime when subjected to multiaxial tension/torsion loadings.

scholarly journals Internal Crack Initiation and Growth Starting from Artificially Generated Defects in Additively Manufactured Ti6Al4V Specimen in the VHCF Regime

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5315
Author(s):  
Carsten Wickmann ◽  
Christopher Benz ◽  
Horst Heyer ◽  
Kerstin Witte-Bodnar ◽  
Jan Schäfer ◽  
...  
Keyword(s):  
Focused Ion Beam ◽  
Fatigue Testing ◽  
Early Stage ◽  
Ion Beam ◽  
Fatigue Tests ◽  
Internal Crack ◽  
Very High Cycle Fatigue ◽  
Ultrasonic Fatigue ◽  
Experimental Findings ◽  
Very High

The aim of the present work was to investigate the ‘fine granular area’ (FGA) formation based on artificially generated internal defects in additively manufactured Ti6Al4V specimens in the early stage of fatigue crack growth in the ‘very high cycle fatigue’ (VHCF) regime. Fatigue tests were performed with constant amplitude at pure tension-compression loading (R = −1) using an ultrasonic fatigue testing setup. Failed specimens were investigated using optical microscopy, high-resolution ‘scanning electron microscopy’ (SEM), and ‘focused ion beam’ (FIB) techniques. Further, the paper introduces alternative proposals to identify the FGA layer beneath the fracture surfaces in terms of the ‘cross section polishing’ (CSP) technique and metallic grindings with special attention paid to the crack origin, the surrounding microstructure, and the expansion of the nanograin layer beneath the fracture surface. Different existing fracture mechanical approaches were applied to evaluate if an FGA formation is possible. Moreover, the results were discussed in comparison to the experimental findings.

Gigacycle Fatigue of Welded Joints of Structural Materials (A Review)

2016 ◽  
Vol 17 ◽  
pp. 14-30 ◽  
Author(s):  
Okechukwu P. Nwachukwu ◽  
Alexander V. Gridasov ◽  
Ekaterina A. Gridasova
Keyword(s):  
Fatigue Testing ◽  
Fatigue Behavior ◽  
Testing Machine ◽  
Structural Materials ◽  
Fatigue Tests ◽  
Material Defects ◽  
Graphite Cast Iron ◽  
Ultrasonic Fatigue ◽  
Materials Used ◽  
Fatigue Failures

This review looks into the state of gigacycle fatigue behavior of some structural materials used in engineering works. Particular attention is given to the use of ultrasonic fatigue testing machine (USF-2000) due to its important role in conducting gigacycle fatigue tests. Gigacycle fatigue behavior of most materials used for very long life engineering applications is reviewed.Gigacycle fatigue behavior of magnesium alloys, aluminum alloys, titanium alloys, spheroid graphite cast iron, steels and nickel alloys are reviewed together with the examination of the most common material defects that initiate gigacycle fatigue failures in these materials. In addition, the stage-by-stage fatigue crack developments in the gigacycle regime are reviewed. This review is concluded by suggesting the directions for future works in gigacycle fatigue.

scholarly journals Recent Advances in Very High Cycle Fatigue Behavior of Metals and Alloys—A Review

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1200
Author(s):  
Ashutosh Sharma ◽  
Min Chul Oh ◽  
Byungmin Ahn
Keyword(s):  
Crack Initiation ◽  
High Cycle Fatigue ◽  
Fatigue Testing ◽  
Fatigue Behavior ◽  
Simulation Studies ◽  
Cycle Fatigue ◽  
Future Directions ◽  
Very High Cycle Fatigue ◽  
Ultrasonic Fatigue ◽  
Very High

We reviewed the research and developments in the field of fatigue failure, focusing on very-high cycle fatigue (VHCF) of metals, alloys, and steels. We also discussed ultrasonic fatigue testing, historical relevance, major testing principles, and equipment. The VHCF behavior of Al, Mg, Ni, Ti, and various types of steels were analyzed. Furthermore, we highlighted the major defects, crack initiation sites, fatigue models, and simulation studies to understand the crack development in VHCF regimes. Finally, we reviewed the details regarding various issues and challenges in the field of VHCF for engineering metals and identified future directions in this area.

Effect of shot peening on very high cycle fatigue of 2024-T351 aluminium alloy

2020 ◽  
Vol 10 (7) ◽  
pp. 1032-1039
Author(s):  
Renhui Tian ◽  
Jiangfeng Dong ◽  
Yongjie Liu ◽  
Qingyuan Wang ◽  
Yunrong Luo
Keyword(s):  
Fracture Surface ◽  
Crack Initiation ◽  
Shot Peening ◽  
High Cycle Fatigue ◽  
Fatigue Tests ◽  
Cycle Fatigue ◽  
Very High Cycle Fatigue ◽  
Fatigue Strength Improvement ◽  
Ultrasonic Fatigue ◽  
Very High

To investigate the influence of shot peening (SP) on very high cycle fatigue (VHCF) performance of 2024-T351, the specimens with three surface conditions were performed under ultrasonic fatigue tests: mechanicallypolished without peening (NP), ceramic shot peening (SP1), steel and glass mixed shot peening (SP2). The roughness, microhardness, residual stress, fractography measurement and scanning electron microscopy (SEM) were applied before fatigue test to characterize the effective layer induced by the peening treatment. For the failed specimens, the fracture surface were analysed using SEM to study the mechanisms of fatigue crack propagation. In addition, the fatigue life curve in ultra-high cycle region continuously decreased in the three series of specimens. However, the experimental results revealed that fatigue strength improvement resulting from shot peening treatment was negligible in very high cycle regime. Furthermore, the stress intensity factor for the surface crack initiation (SCI) and interior crack initiation (ICI) was discussed based on quantitative analysis on the fracture surface. The average values of ΔKfish-eye for NP, SP1 and SP2 specimens are about 2.22, 1.48 and 1.61 MPa · m1/2, respectively.

Fatigue in Ti-6Al-4V at Very High Cycles

2007 ◽  
Vol 561-565 ◽  
pp. 259-262 ◽  
Author(s):  
X.J. Cao ◽  
M.R. Sriraman ◽  
Qing Yuan Wang
Keyword(s):  
Fatigue Testing ◽  
Fatigue Behavior ◽  
Weight Ratio ◽  
High Strength ◽  
Ambient Air ◽  
Ti Alloys ◽  
Structural Applications ◽  
Ultrasonic Fatigue ◽  
Reversed Loading ◽  
Very High

The importance of determining and understanding the very high cycle fatigue behaviors of materials has gained strength in recent years. Ti-alloys, in view of their high strength-to-weight ratio, have a range of structural applications. Of these, Ti-6Al-4V, belonging to the alpha-beta type is the most widely used. The present paper deals with investigations on the fatigue behavior of TC4, the Chinese equivalent to Ti-6Al-4V, up to very high cycles. Fatigue testing was carried out on a piezoelectric ultrasonic fatigue machine operating at 20 kHz frequency. Hourglass shaped resonant specimens were tested in ambient air at room temperature under completely reversed loading conditions (R = -1). Failure in the alloy was seen to occur right up to the gigacycle regime, with the fractures being found to initiate from the surface unlike in steels. The fracture surfaces exhibit brittle characteristics containing river patterns and cleavage facets, as well as striations.

Very High Cycle Fatigue in Pulsed High Power Spallation Neutron Source

2014 ◽  
Vol 891-892 ◽  
pp. 536-541 ◽  
Author(s):  
Zhi Hong Xiong ◽  
Masatoshi Futakawa ◽  
Takashi Naoe ◽  
Katsuhiro Maekawa
Keyword(s):  
Strain Rate ◽  
High Cycle Fatigue ◽  
Fatigue Testing ◽  
Testing Machine ◽  
Air Cooling ◽  
Cycle Fatigue ◽  
Very High Cycle Fatigue ◽  
Neutron Spallation Source ◽  
Ultrasonic Fatigue ◽  
Very High

Very high cycle fatigue degradation of type 316L austenitic stainless steel, which is used as the structural material of neutron spallation sources under intensive neutron irradiation environment, is investigated by using an ultrasonic fatigue testing machine. The strain rate imposed on the structure of neutron spallation source is almost equivalent to that produced in the testing machine. The temperature on the surface was controlled by the air-cooling. The effect of strain rate on the fatigue strength is recognized to increase the fatigue limit.

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