Effect of Residual Stress, Temperature and Adhesion on Wheel Surface Fatigue Cracking

2008 ◽  
Author(s):  
Daniel H. Stone ◽  
Scott M. Cummings
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Contact Stress ◽  
Fatigue Cracking ◽  
Fatigue Tests ◽  
Operating Conditions ◽  
Defect Prevention ◽  
Class C ◽  
Research Consortium

The Wheel Defect Prevention Research Consortium (WDPRC) conducted an analysis pertaining to the fatigue cracking of wheel treads by incorporating the effects of residual stresses, temperature, and wheel/rail contact stress. Laboratory fatigue tests were conducted on specimens of wheel tread material under a variety of conditions allowing the analysis to properly account for the residual stresses accumulated in normal operating conditions. Existing literature was used in the analysis in consideration of the effects of contact stress and residual stress relief. This project was performed to define a temperature range in which the life of an AAR Class C wheel is not shortened by premature fatigue and shelling. Wayside wheel thermal detectors are becoming more prevalent on North American railroads as a means of identifying trains, cars, and wheels with braking issues. Yet, from a wheel fatigue perspective, the acceptable maximum operating temperature remains loosely defined for AAR Class C wheels. It was found that residual compressive circumferential stresses play a key role in protecting a wheel tread from fatigue damage. Therefore, temperatures sufficient to relieve residual stresses are a potential problem from a wheel fatigue standpoint. Only the most rigorous braking scenarios can produce expected train average wheel temperatures approaching the level of concern for reduced fatigue life. However, the variation in wheel temperatures within individual cars and between cars can result in temperatures high enough to cause a reduction in wheel fatigue life.

EFFECT OF CERAMIC COATING THICKNESS ON RESIDUAL STRESS AND FATIGUE CHARACTERISTIC OF 1Cr-1Mo-0.25V STEEL

2002 ◽  
Vol 16 (01n02) ◽  
pp. 181-188 ◽  
Author(s):  
CHANG-MIN SUH ◽  
BYUNG-WON HWANG ◽  
KYUNG-RYUL KIM
Keyword(s):  
Residual Stress ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Coating Thickness ◽  
Fatigue Behavior ◽  
Fatigue Crack Initiation ◽  
Turbine Rotor ◽  
Fatigue Tests ◽  
Rotor Steel

To evaluate the effect of coatings on the fatigue behaviors of turbine rotor steel, TiN and TiAlN films were deposited on the 1Cr-1Mo-0.25V steels by arc-ion plating (AIP) method with and wihtout screen ion filter. The coating thickness were varied with 2.5 μm, 3.5 μm, and 5.0 μm. A Cu-K α beam source was used as a characteristic X-ray and the crystal plane of (422) was selected to evaluate the residual stresses. In order to clear the relationship between fatigue behavior and residual stress of specimen coated with TiN and TiAlN films, the fatigue tests of specimens with and without coating were carried out at room temperatures respectively. It is shown that the fatigue life of the coated specimen was longer than that of uncoated specimen. The compressive residual stresses on the coatings were higher, and the fatigue crack initiated at an inclusion in the substrate near bond interface. It is known that compressive residual stress caused by hard coating would retard the fatigue crack initiation on the specimen surface, and then led to fatigue strength and fatigue life increasing.

Effect of Residual Stress or Plastic Deformation History on Fatigue Life Simulation of Pipeline Dents

2018 ◽  
Author(s):  
Xian-Kui Zhu ◽  
Rick Wang
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Strain History ◽  
Deformation History ◽  
Stress Strain ◽  
Element Analysis ◽  
Fea Model

Mechanical dents often occur in transmission pipelines, and are recognized as one of major threats to pipeline integrity because of the potential fatigue failure due to cyclic pressures. With matured in-line-inspection (ILI) technology, mechanical dents can be identified from the ILI runs. Based on ILI measured dent profiles, finite element analysis (FEA) is commonly used to simulate stresses and strains in a dent, and to predict fatigue life of the dented pipeline. However, the dent profile defined by ILI data is a purely geometric shape without residual stresses nor plastic deformation history, and is different from its actual dent that contains residual stresses/strains due to dent creation and re-rounding. As a result, the FEA results of an ILI dent may not represent those of the actual dent, and may lead to inaccurate or incorrect results. To investigate the effect of residual stress or plastic deformation history on mechanics responses and fatigue life of an actual dent, three dent models are considered in this paper: (a) a true dent with residual stresses and dent formation history, (b) a purely geometric dent having the true dent profile with all stress/strain history removed from it, and (c) a purely geometric dent having an ILI defined dent profile with all stress/strain history removed from it. Using a three-dimensional FEA model, those three dents are simulated in the elastic-plastic conditions. The FEA results showed that the two geometric dents determine significantly different stresses and strains in comparison to those in the true dent, and overpredict the fatigue life or burst pressure of the true dent. On this basis, suggestions are made on how to use the ILI data to predict the dent fatigue life.

Analysis of circumferentially welded thin-walled cylinders to study the effects of tack weld orientations and joint root opening on residual stress fields

2009 ◽  
Vol 223 (5) ◽  
pp. 1037-1049 ◽  
Author(s):  
N U Dar ◽  
E M Qureshi ◽  
A M Malik ◽  
M M I Hammouda ◽  
R A Azeem
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Arc Welding ◽  
Operating Conditions ◽  
Stress Fields ◽  
Welded Structures ◽  
Prime Concern ◽  
Thin Walled ◽  
Tack Weld ◽  
Welding Processes

In recent years, the demand for resilient welded structures with excellent in-service load-bearing capacity has been growing rapidly. The operating conditions (thermal and/or structural loads) are becoming more stringent, putting immense pressure on welding engineers to secure excellent quality welded structures. The local, non-uniform heating and subsequent cooling during the welding processes cause complex thermal stress—strain fields to develop, which finally leads to residual stresses, distortions, and their adverse consequences. Residual stresses are of prime concern to industries producing weld-integrated structures around the globe because of their obvious potential to cause dimensional instability in welded structures, and contribute to premature fracture/failure along with significant reduction in fatigue strength and in-service performance of welded structures. Arc welding with single or multiple weld runs is an appropriate and cost-effective joining method to produce high-strength structures in these industries. Multi-field interaction in arc welding makes it a complex manufacturing process. A number of geometric and process parameters contribute significant stress levels in arc-welded structures. In the present analysis, parametric studies have been conducted for the effects of a critical geometric parameter (i.e. tack weld) on the corresponding residual stress fields in circumferentially welded thin-walled cylinders. Tack weld offers considerable resistance to the shrinkage, and the orientation and size of tacks can altogether alter stress patterns within the weldments. Hence, a critical analysis for the effects of tack weld orientation is desirable.

Stress and Fatigue Life Modeling of Cannon Breech Closures Including Effects of Material Strength and Residual Stress

2000 ◽  
Vol 123 (1) ◽  
pp. 150-154
Author(s):  
John H. Underwood ◽  
Michael J. Glennon
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Fatigue Life ◽  
Yield Strength ◽  
Residual Stresses ◽  
Solid Mechanics ◽  
Element Model ◽  
Pressure Vessels ◽  
Material Strength ◽  
Element Analysis

Laboratory fatigue life results are summarized from several test series of high-strength steel cannon breech closure assemblies pressurized by rapid application of hydraulic oil. The tests were performed to determine safe fatigue lives of high-pressure components at the breech end of the cannon and breech assembly. Careful reanalysis of the fatigue life tests provides data for stress and fatigue life models for breech components, over the following ranges of key parameters: 380–745 MPa cyclic internal pressure; 100–160 mm bore diameter cannon pressure vessels; 1040–1170 MPa yield strength A723 steel; no residual stress, shot peen residual stress, overload residual stress. Modeling of applied and residual stresses at the location of the fatigue failure site is performed by elastic-plastic finite element analysis using ABAQUS and by solid mechanics analysis. Shot peen and overload residual stresses are modeled by superposing typical or calculated residual stress distributions on the applied stresses. Overload residual stresses are obtained directly from the finite element model of the breech, with the breech overload applied to the model in the same way as with actual components. Modeling of the fatigue life of the components is based on the fatigue intensity factor concept of Underwood and Parker, a fracture mechanics description of life that accounts for residual stresses, material yield strength and initial defect size. The fatigue life model describes six test conditions in a stress versus life plot with an R2 correlation of 0.94, and shows significantly lower correlation when known variations in yield strength, stress concentration factor, or residual stress are not included in the model input, thus demonstrating the model sensitivity to these variables.

An Analysis of Residual Stress Improvement for a Dissimilar Metal Nozzle-to-Pipe Weld by Using the Heat Sink Method

2008 ◽  
Author(s):  
J.-S. Park ◽  
J.-M. Kim ◽  
G.-H. Sohn ◽  
Y.-H. Kim
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Heat Sink ◽  
Nuclear Power ◽  
Power Plants ◽  
Base Alloy ◽  
Fatigue Cracking ◽  
Hole Drilling ◽  
Fe Model ◽  
Dissimilar Metal

This study is concerned with the mechanics analysis of residual stress improvement by the heat sink method applied to a dissimilar metal weld (DMW) for the use in nuclear power plants. The DMW joint considered here is composed of ferritic low-alloy steel nozzle, austenitic stainless steel safe-end, and nickel-base alloy A52 weld metal. To prepare the DMW joint with a narrow-gap, the gas tungsten arc welding (GTAW) process is utilized, and the heat sink method is employed to control thermal gradients developed in the critical region of work pieces during welding. Weld residual stresses are computed by the non-linear thermal elasto-plastic analysis using the axisymmetric finite element (FE) model, for which temperature-dependent thermal and mechanical properties of the materials are considered. A full-scale mock-up test is conducted to validate analytical solution for the DMW joint, and residual stresses are measured by using the hole-drilling method. Results of the FE modeling and mock-up test for the DMW joint are compared and effects of the heat sink method are discussed. It is found that a significant amount of residual compressive stresses can be developed on the inner surface of the DMW joint by using the heat sink method, which can effectively reduce the susceptibility of the welded materials to stress corrosion or fatigue cracking.

The Influence of Residual Stress on Fatigue Cracking

1990 ◽  
Vol 112 (3) ◽  
pp. 199-203 ◽  
Author(s):  
A. Okamoto ◽  
H. Nakamura
Keyword(s):  
Residual Stress ◽  
Crack Growth ◽  
Surface Crack ◽  
Low Carbon Steel ◽  
Fatigue Cracking ◽  
Fatigue Tests ◽  
Power Relationship ◽  
Low Carbon ◽  
Nonlinear Stress ◽  
Inner Surface

The influence of residual stress on fatigue crack growth was experimentally and analytically investigated for surface cracks. Fatigue tests were performed on straight pipes of low-carbon steel with a circumferential inner surface crack in laboratory air environment. Some of the test pipes had been subjected to special heat treatments so as to have compressive or tensile residual stresses along inner surface. The results show that the compressive residual stress remarkably suppresses the surface crack growth, while the tensile residual stress does not accelerate the crack growth very much. The crack growth analyses were conducted by the application of power relationship between ΔK and da/dN. The stress intensity factors due to the nonlinear stress field were calculated by the weight function method. The analyses resulted in a confirmation of the behavior of the crack growth observed in the experiments.

A First Investigation on Cumulative Fatigue Life for a Type 304-L Stainless Steel Used for Pressure Water Reactor

2009 ◽  
Author(s):  
A. Fissolo ◽  
J. M. Stelmaszyk
Keyword(s):  
Stainless Steel ◽  
Fatigue Life ◽  
Fatigue Tests ◽  
Operating Conditions ◽  
Damage Effect ◽  
Final Conclusion ◽  
Variable Loading ◽  
Miner’S Rule ◽  
Miner's Rule ◽  
Type 304

In order to estimate the crack initiation damage, and also the water leakage conditions on PWR pipes, uniaxial fatigue curves are often used. They were deduced from strain or stress load control tests using normalised cylindrical specimens. However, severe thermo-mechanical loading fluctuations are observed in operating conditions. Components may also be submitted to transient loadings. The purpose of the present work is to start investigation on the fatigue life with a variable loading, in order to examine cumulative damage effect in fatigue. In this frame, multilevel strain controlled fatigue tests have been performed on a Type 304-L stainless steel (elaborated in accordance with the RCC-M specifications). The experimental results show that linear Miner’s rule is not verified in our conditions. When the strains are applied in a decreasing order (High-Low strain sequence), the summation of cycle ratios is smaller than unity, whatever the number of applied levels, whereas this summation is higher than one for an increasing order (Low-High strain sequence). A loading sequence effect is clearly evidenced. Different cumulative fatigue damage theories, proposed in literature, have been also tested. Some of them have been given better estimation than the Miner’s rule. That is the case of the so-called “Hybrid Theory” proposed and tested before by Bui Quoc on a Type 304-L steel. Extension of a model proposed by S. Taheri would seem also promising. At this stage, final conclusion cannot be yet deduced, additional investigations are needed.

Residual Stress in Tools and Components in Case of Thermo-Mechanical Metal Forming Processes

2011 ◽  
Vol 681 ◽  
pp. 340-345 ◽  
Author(s):  
Alexander Grüning ◽  
Markus Lebsanft ◽  
Berthold Scholtes
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Process Parameters ◽  
Cyclic Stress ◽  
Fatigue Tests ◽  
Manufacturing Operations ◽  
Challenging Tasks ◽  
Steel Aisi ◽  
Stress States ◽  
Adapted Process

Residual stresses play a key role in thermo-mechanically coupled forming processes for industrial mass production. They are an unavoidable consequence of the alternating inhomogeneous fields of temperature and mechanical stress developing in tools and components dependent on the process parameters applied. Because of their influence on the behavior of the components produced, a great interest exists to get reliable information about origin and distribution of the relevant residual stress fields and to understand the basic principles of their formation. In this paper the development of residual stress in tools (steel AISI H11) used for the thermo-mechanical forming operation of cylindrical flange shafts (steel SAE 6150) is outlined. The loading situation of the tool is simulated by thermal fatigue tests, providing information about cyclic stress and plastic deformation during the manufacturing process. Furthermore the residual stress states of the flange shafts manufactured are presented and discussed. Chip forming manufacturing operations are challenging tasks and tensile residual stresses can be avoided using adapted process parameters.

scholarly journals Residual Stresses in Passenger Car Wheels

2006 ◽  
Author(s):  
Shuangqin Liu ◽  
Benjamin Perlman ◽  
Jeffrey Gordon
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Residual Stresses ◽  
Residual Stress Distribution ◽  
Operating Conditions ◽  
Computational Time ◽  
Passenger Car ◽  
3 Dimensional ◽  
Dimensional Modeling ◽  
Service Loading

Knowledge of the residual stress state in wheels resulting from manufacturing and subsequent service loading is useful for several practical reasons. The ability to estimate residual stress levels permits the tuning of manufacturing processes to control the magnitude and distribution of these stresses in new wheels in order to achieve safe performance in service. Similarly, understanding the redistribution of residual stresses following application of service loads (wheel/rail contact and thermal stresses) is crucial to avoid operating conditions which may lead to premature wheel failure. Axisymmetric (2-dimensional) analyses are typically performed in order to conduct manufacturing process simulations since these processes affect the entire wheel in a circumferentially uniform sense. Generally, analyses involving service loading have sought to identify the "shakedown state" at which the residual stress distribution stabilizes after some number of loading cycles. In order to properly account for service loads, 3-dimensional models are required since contact and brake shoe thermal loading are not axisymmetric. Since the as-manufactured residual stress distribution must be considered in a service loading simulation, 3-dimensional modeling of this process is required. This paper presents a preliminary comparison of 2- and 3-dimensional modeling of the wheel heat treatment process. Except for the increased computational time required for the 3-dimensional analysis, the results agree favorably. The 3-dimensional model is used to simulate service loads involving wheel-rail contact loading representative of a typical passenger car. The model is exercised with a variety of material models for comparison with previous work. Results are presented for multiple loading scenarios and shakedown stress states are established for a range of applied loads.

RETROFITTING METHODS AGAINST FATIGUE CRACKING IN STEEL GIRDER WEB PENETRATION

2019 ◽  
Vol 6 (1) ◽  
Author(s):  
Chihiro Sakamoto ◽  
Masahiro Sakano ◽  
Hideyuki Konishi ◽  
Takashi Fujii
Keyword(s):  
Fatigue Life ◽  
Fatigue Cracking ◽  
Highway Bridges ◽  
Lower Surface ◽  
Strength Properties ◽  
Fatigue Tests ◽  
Stress Distributions ◽  
Steel Girder ◽  
Cracking Behavior ◽  
Weld Toe

Fatigue cracking in steel girder web penetration details is so dangerous that it can break steel girders. Since a number of highway bridges have such web penetration details in Japan, it is of urgent importance to grasp these fatigue strength properties and develop effective retrofitting methods. In a previous report, we investigated the stress distributions around web penetration details, and fatigue cracking behavior, using steel girder specimens with web penetration details. In this study, we investigate effects of retrofitting methods against fatigue cracking in web penetration details through fatigue tests using large girder specimens with web penetration details in which cross beam lower flanges are connected to lower surface of a slot by welding. Principal results obtained through this study are as follows: (1) Weld toe grinding can extend fatigue life more than 5 times, (2) Two-face attachment can extend fatigue life more than 10 times, and (3) Two-face attachment with weld toe grinding can extend fatigue life more than 25 times.

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