Influence of the interphase between laser-cladded metal layer and steel substrate on fatigue propagation of a short edge crack

Laser cladding is a relatively new technology how to combine properties of various materials. Thus, bi-material interfaces are presented in real structures and can affect the fatigue crack propagation. A cracked bar subjected to pure tensile loading is numerically simulated in this work in order to analyze the effect of the interphase layer between the cladded metal layer and the steel substrate on crack growth in the surface layer. Particularly, the influence of various Young’s modulus of the interphase on the stable/unstable edge crack propagation is assessed. Moreover, the number of cycles necessary for achievement of the defined critical crack length is calculated and it is summarized that knowledge of elastic properties of the thin interphase is crucial for fracture and fatigue analyses.

Damage Tolerance Assessment of Multi-Hull Aluminum Vessels Using Global Finite Element Methods

As aluminum high-speed multi-hulls continue to grow in size, capacity and operational sea state, a need is growing to understand the damage tolerance of these structures. This paper presents a Linear Elastic Fracture Mechanics (LEFM) approach to performing damage tolerance assessments of aluminum hull structures using the hydrodynamic analysis and global finite element model developed as part of a class Dynamic Loading Approach (DLA) notation. The LEFM approach is used to calculate the stress intensity factor (K) and the critical crack length throughout the model to screen the entire hull structure and identify fracture critical locations. This paper also investigates the use of elastic-plastic fracture mechanics to predict potential critical crack growth locations, rates, and directions. Fracture critical locations identified and visualized through the analysis provide the ship designer with tools to develop damage tolerant structures. The results of the analysis can also assist owners and regulatory bodies in developing structural inspection and repair plans.

From sub-Rayleigh to intersonic crack propagation in snow slab avalanche release

<p>Snow slab avalanche release can be separated in four distinct phases : (i) failure initiation in a weak snow layer buried below a cohesive snow slab, (ii) the onset and, (iii) dynamic phase of crack propagation within the weak layer across the slope and (iv) the slab release. The highly porous character of the weak layer implies volumetric collapse during failure which leads to the closure of crack faces followed by the onset of frictional contact. To better understand the mechanisms of dynamic crack propagation, we performed numerical simulations, snow fracture experiments, and analyzed the release of full scale avalanches. Simulations of crack propagation are based on the Material Point Method (MPM) and finite strain elastoplasticity. Experiments consist of the so-called Propagation Saw Test (PST). Concerning full scale measurements, an algorithm is applied to detect changes in image pixel intensity induced by slab displacements. We report the existence of a transition from sub-Rayleigh anticrack to supershear crack propagation following the Burridge-Andrews mechanism. In detail, after reaching the critical crack length, self-propagation starts in a sub-Rayleigh regime and is driven by slab bending induced by weak layer collapse. If the slope angle is larger than a critical value, and if a so-called super critical crack length is reached, supershear crack propagation occurs. The corresponding critical angle may be lower than the weak layer friction angle due to the loss of frictional resistance during volumetric collapse. The sub-Rayleigh regime is driven by mixed mode anticrack propagation while the supershear regime corresponds to a pure mode II propagation with intersonic crack speeds (v: crack speed, c<sub>s</sub>: shear wave speed, c<sub>p</sub>: longitudinal wave speed, E: slab Young's modulus and ρ: slab density). This intersonic regime of crack propagation thus leads to pure tensile slab fractures initiating from the bottom of the slab as opposed to top initiations induced by slab bending in the sub-Rayleigh regime. Key ingredients for the existence of this transition are discussed such as the role played by friction angle, collapse height and slab secondary fractures. </p>

FRACTURE SIMULATION IN POLYMER NANOCOMPOSITES USING MOLECULAR DYNAMICS

The objective of this paper is to (a) investigate the validity of application of continuum-based linear elastic fracture mechanics (LEFM) methodology, which is often employed by researchers to model fracture processes at the “discrete” atomic scale, and (b) to study the effect of nanographene platelet size on the rupture strength of an edge-cracked polymer block. The material selected for this study is EPON 862 epoxy polymer with 85% cross-link density. Further, an atomistic J-integral is implemented as a nano-scale fracture metric to investigate flaw-tolerance at the nanoscale reported by many researchers, and to develop a methodology to predict the initiation fracture toughness of the material. For this purpose, a bond-order based potential (ReaxFF) available in LAMMPS , a molecular dynamics (MD) software, is utilized. Predictions obtained using the atomistic J-integral are compared with LEFM predictions for the case of a cross-linked epoxy polymer block with a center-crack under uniform far-field loading. Significant deviations from LEFM for crack-lengths below a certain critical crack-length threshold are observed. Further, far-field stress vs. strain plots are obtained for an edge-cracked epoxy polymer block with a single 14 nm graphene nanoplatelet embedded ahead of the crack tip and it is compared with stress vs. strain plot obtained for the same epoxy block with two 7 nm graphene nanoplatelets embedded ahead of the crack tip to study platelet size effect. Significant size effect was observed as shown in the results.

Numerical Prediction of the Bending Fatigue Crack Propagation Behaviour in Asymmetric Spur Gears

The damage tolerance of a component is crucial for achieving a reliable and smooth operation. The crack propagation in a spur gear critically affects the performance of the transmission system. Asymmetric gears are used for enhancing the load-carrying capacity by increasing the pressure angle of a flank beyond the conventional limits. In this study, the effect of initial crack inclination angle and length in the tooth fillet region on the Stress Intensity Factor (SIF) and the crack path of an asymmetric gear (34°/20°) were studied using numerical simulations. Quasi-static analyses were performed in FRANC2D. The crack propagation life was calculated using Paris law. Results revealed that tooth asymmetry has no effect on the crack path. However, asymmetric tooth form caused a reduction in the SIF value and increased the critical crack length, leading to an increased crack propagation life and damage tolerance.

On Modeling of Vibration and Crack Growth in a Rotor for Prognostics

Prognostics and health management (PHM) include comprehensive engineering approaches that evaluate the real-time health condition of an asset and predict its future states under the actual operating conditions. This predictive ability would result in efficient maintenance approaches such as Condition Based Maintenance (CBM) that can set maintenance strategies optimally and reduce the life cycle costs. Diagnostics and Prognostics are two major concepts in PHM. Detection, Isolation and Identification of faults are done by diagnostics while prognostics deals with estimation of future states. Mechanical fatigue phenomenon that causes crack initiation and propagation is considered as a common reason for failure in mechanical parts. Hence, diagnostics and prognostics of the crack initiation and propagation have been the subject of many research papers recently. The current paper presents a diagnostics and prognostics method capable of detecting the crack initiation and propagation in a rotor under cyclic loading. At the first step, the coupled equations of rotor motion and crack growth are obtained. An extended model of Paris–Erdogan equation is used for crack growth modeling. The coupled equations are solved numerically. A set of features are extracted from the dynamic response of the rotor for a range of crack lengths. A dataset is compiled including features of response, operating frequency, crack length and number of cycles remained until reaching the critical crack length. With the objective of generalization of the results, the dataset is used for creating a model using an Artifical Neural Network (ANN). In the trained ANN the inputs are the operating speed and the outputs are the crack length and the remaining useful life (RUL) that address the diagnostics and prognostics objectives, respectively.

Sensitivity of modeled snow stability data to meteorological input uncertainty

To perform spatial snow cover simulations for numerical avalanche forecasting, interpolation and downscaling of meteorological data are required, which introduce uncertainties. The repercussions of these uncertainties on modeled snow stability remain mostly unknown. We therefore assessed the contribution of meteorological input uncertainty to modeled snow stability by performing a global sensitivity analysis. We used the numerical snow cover model SNOWPACK to simulate two snow instability metrics, i.e., the skier stability index and the critical crack length, for a field site equipped with an automatic weather station providing the necessary input for the model. Simulations were performed for a winter season, which was marked by a prolonged dry period at the beginning of the season. During this period, the snow surface layers transformed into layers of faceted and depth hoar crystals, which were subsequently buried by snow. The early-season snow surface was likely the weak layer of many avalanches later in the season. Three different scenarios were investigated to better assess the influence of meteorological forcing on snow stability during (a) the weak layer formation period, (b) the slab formation period, and (c) the weak layer and slab formation period. For each scenario, 14 000 simulations were performed, by introducing quasi-random uncertainties to the meteorological input. Uncertainty ranges for meteorological forcing covered typical differences observed within a distance of 2 km or an elevation change of 200 m. Results showed that a weak layer formed in 99.7 % of the simulations, indicating that the weak layer formation was very robust due to the prolonged dry period. For scenario a, modeled grain size of the weak layer was mainly sensitive to precipitation, while the shear strength of the weak layer was sensitive to most input variables, especially air temperature. Once the weak layer existed (case b), precipitation was the most prominent driver for snow stability. The sensitivity analysis highlighted that for all scenarios, the two stability metrics were mostly sensitive to precipitation. Precipitation determined the load of the slab, which in turn influenced weak layer properties. For cases b and c, the two stability metrics showed contradicting behaviors. With increasing precipitation, i.e., deep snowpacks, the skier stability index decreased (became less stable). In contrast, the critical crack length increased with increasing precipitation (became more stable). With regard to spatial simulations of snow stability, the high sensitivity to precipitation suggests that accurate precipitation patterns are necessary to obtain realistic snow stability patterns.

Analytical model for assessing fatigue limit of welded joints of ferritic-pearlitic steels

Introduction. Microdefects and zones with stress concentration in welded joints cause fatigue macrocracks. Such damage is potentially dangerous, especially if the fatigue life of the structure is almost exhausted. In this case, the crack size is close to the critical value, and it is crucial to determine its length. The paper considers the development of an engineering analytical model for assessing the critical crack length and endurance limit of welded joints with the formed grain in the structure of ferrite-pearlitic steels after welding. Materials and Methods. The theory and methods of fracture mechanics at the mesoscale are used. A simple analytical dependence is obtained, which provides determining the critical dimensions of a macrocrack for ferrite-pearlite steels without using the Griffiths formula. . The calculation results of the critical crack lengths of various steels depending on their yield strength are presented. An analytical dependence of the endurance limit calculation for the most dangerous symmetric loading cycle, according to the standard set of mechanical characteristics and the average grain diameter of ferrite-pearlite steel, is presented. Results. Structural deformation analysis of the crack propagation process has been performed. On its basis, an engineering technique for assessing the endurance limit is developed. A mathematical model that enables to calculate the endurance limit and the critical crack length in the components of welded assemblies of large-sized facilities, considering periodic loads of a symmetrical cycle, is developed. Using this model, it is possible to estimate the degree of metal sensitivity to the original characteristics (yield stress, Poisson's ratio, grain diameter, relative constriction, Young's modulus, power-law hardening coefficient, etc.).Discussion and Conclusion. Under stresses corresponding to the steel endurance limit, the critical crack opening rates of the tip and edges approach each other. Energetically, this moment approximately corresponds to the transition of the crack to an unstable state. The accumulation of one-sided plastic deformations causes the limiting state of plasticity of the region adjacent to the crack tip and its avalanche-like or sharply accelerated motion. This critical area is interrelated with the grain diameter of the material, the characteristic of critical plasticity and the critical opening at the crack tip at the fatigue limit. The proposed analytical dependences can be used to assess the residual life and the fatigue limit of welded structures, the influence of various factors on the fatigue limit of welded joints of ferrite-pearlitic steels used in mechanical engineering, shipbuilding, pipeline transport, etc

The RHOSSA campaign: multi-resolution monitoring of the seasonal evolution of the structure and mechanical stability of an alpine snowpack

The necessity of characterizing snow through objective, physically motivated parameters has led to new model formulations and new measurement techniques. Consequently, essential structural parameters such as density and specific surface area (for basic characterization) or mechanical parameters such as the critical crack length (for avalanche stability characterization) gradually replace the semiempirical indices acquired from traditional stratigraphy. These advances come along with new demands and potentials for validation. To this end, we conducted the RHOSSA field campaign, in reference to density (ρ) and specific surface area (SSA), at the Weissfluhjoch research site in the Swiss Alps to provide a multi-instrument, multi-resolution dataset of density, SSA and critical crack length over the complete winter season of 2015–2016. In this paper, we present the design of the campaign and a basic analysis of the measurements alongside predictions from the model SNOWPACK. To bridge between traditional and new methods, the campaign comprises traditional profiles, density cutter, IceCube, SnowMicroPen (SMP), micro-computed-tomography, propagation saw tests and compression tests. To bridge between different temporal resolutions, the traditional weekly to biweekly (every 2 weeks, used in this sense throughout the paper) snow pits were complemented by daily SMP measurements. From the latter, we derived a recalibration of the statistical retrieval of density and SSA for SMP version 4 that yields an unprecedented spatiotemporal picture of the seasonal evolution of density and SSA in a snowpack. Finally, we provide an intercomparison of measured and modeled estimates of density and SSA for four characteristic layers over the entire season to demonstrate the potential of high-temporal-resolution monitoring for snowpack model validation.

Plastic Limit Pressure Solutions for Elbows With Slant Through-Wall Cracks

For leak-before-break (LBB) assessment, an idealized through-wall crack (TWC) is typically postulated to determine the critical crack length of cracked piping. However, such an idealization in terms of crack shape can lead to underestimations of plastic limit pressure. Although many studies have been performed to obtain accurate limit load solutions for cracked straight pipes by considering realistic crack geometries, there is still a lack of information regarding slant TWC at elbow. Therefore, three-dimensional finite element (FE) models of an elbow considering the effects of slant TWC on plastic limit pressure are developed. The proposed FE model and analysis procedure were verified through comparisons to the existing solutions for idealized TWCs in elbow. On this basis, the effect of slant TWC on the plastic limit pressure is analyzed, and a closed-form solution of the plastic limit pressure is proposed, for an elbow containing a longitudinal or a circumferential through-wall crack.