Stress Rupture Life Prediction Method for Notched Specimens Based on Minimum Average Von Mises Equivalent Stress

Creep tests were carried out on notched plate specimens of nickel-based superalloy GH4169 with different stress concentration coefficients. It was found that the duration of the first stage of the creep curve increases with the increase of stress concentration coefficient, while the fracture ductility decreases with the increase of stress concentration coefficient. To predict the life of notched plate specimens, four constitutive models were used to analyze the stress and strain of the notches. It was found that the average Von Mises equivalent stress (AVES) on the minimum notch section first decreases and then increases with the creep time, resulting in a minimum value. The minimum average Von Mises equivalent stress (MAVES) is considered as the characteristic stress of notched specimens in this paper. The creep life equation is fitted according to the results of creep tests of smooth specimens, and then the predicted life of notched specimens is obtained by substituting the minimum average Von Mises equivalent stress of notched specimens into the creep equation. The prediction results of the four constitutive models are within 2 times the dispersion band, and the three-stage model is within the 1.5 times dispersion band.

Modeling and simulation of ductile damage in forged steel used to encapsulate high-level radioactive waste

Andra, the French national radioactive waste management agency, is in charge of studying the disposal of high-level and long-lived intermediate-level waste (HLW and ILW-LL) in a deep geological repository. According to the reference concept, it is planned to encapsulate high-level waste in non-alloy P285NH steel overpacks before inserting them into horizontal steel cased micro-tunnels. This work is a part of the study about the long-term behavior of a welded steel overpack subjected to external hydrostatic pressure and several localized loading paths. Indeed, the main objective of this work is to develop the most suitable model for non-alloy steel P285NH to be used in the prediction of the long-term overpack behavior. Dealing with a ductile steel, elastoplastic constitutive equations accounting for mixed nonlinear isotropic and kinematic hardening strongly coupled with ductile isotropic damage are adopted. They are formulated based on the classical thermodynamics of irreversible processes framework with state variables at the macroscopic scale, (Germain, 1973) (Lemaitre 1985, Saanouni 2012). In this paper, a new coupling formulation between the scalar isotropic ductile damage and the deviatoric and spherical part of the Cauchy stress and elastic strain tensors is proposed. In order to calibrate the developed model on P285NH steel, multiple tensile tests are performed using classical cylindrical specimens, notched specimens and double notched specimens. In the last part, some experimental fields are measured using digital image correlation. Application is made to a simplified overpack represented by thick walled cylinder subject to compressive loading path. A FEM (Finite Element method) crushing operation of an overpack’s cylindrical part has simulated and analysed.

Open hole size effects on tensile properties of 3D braided composites

Owing to the excellent integrated structure, notch-insensitivity, delamination-free characteristics, 3D braided composites have a broad range of engineering applications. In this paper, the notch size effects on two types of 3D braided composites were experimentally examined. Style I incorporated 40% of longitudinal lay-in yarns. Style II was the pure braids. The Point Stress Criterion (PSC) was applied to predict the open-hole strength of 3D braided composites. It is found the 3D braided composites can keep higher proportion residual strength after involving the different circular hole sizes compared to plain woven laminates. The open-hole pure braided specimen shows better performance than that the braids with longitudinal yarns, the lay-in longitudinal yarns improve neither specimens’ un-notched strength, nor the modulus. The predicted open-hole strength were compared with experimental results. The traditional analytical method can predict the open-hole strength of 3D braided composite to some extent. Under uniaxial tensile stress, the failure behaviour of two types of 3D braided specimens are different. For un-notched specimen, clear cracks usually show up on the Style II specimen, while it is not true for Style I coupon. For notched specimen, the crack of both notched specimens will propagate along the notch and finally render the specimen to fail

Fatigue Life Analysis of Aluminum Alloy Notched Specimens under Non-Gaussian Excitation based on Fatigue Damage Spectrum

In this study, a non-Gaussian excitation acceleration method is proposed, using aluminum alloy notched specimens as a research object and measured acceleration signal of a certain airborne bracket, during aircraft flight as input excitations, based on the fatigue damage spectrum (FDS) theory. The kurtosis and skewness of the input signal are calculated and the non-Gaussian characteristics and amplitude distribution are evaluated. Five task segments obey a non-Gaussian distribution, while one task segment obeys a Gaussian distribution. The fatigue damage spectrum calculation method of non-Gaussian excitation is derived. The appropriate FDS calculation method is selected for each task segment and the acceleration parameters are set to construct the acceleration power spectral density, which is equivalent to the pseudo-acceleration damage. A finite-element model is established, the notch stress concentration factor of the specimen is calculated, the large mass point method is used to simulate the shaking table excitation, and a random vibration analysis is carried out to calculate the accelerated fatigue life. The simulation results show that the relative error between the original cumulative damage and test original fatigue life is 15.7%. The shaking table test results show that the relative error of fatigue life before and after acceleration is less than 16.95%, and the relative error of test and simulation is 24.27%. The failure time of the specimen is accelerated from approximately 12 h to 1 h, the acceleration ratio reaches 12, and the average acceleration ideal factor is 1.125, which verifies the effectiveness of the acceleration method. It provides a reference for the compilation of the load spectrum and vibration endurance acceleration test of other airborne aircraft equipment.

Analysis of the Failure Process of Elements Subjected to Monotonic and Cyclic Loading Using the Wierzbicki–Bai Model

This article presents the results of a simulation in which smooth cylindrical and ring-notched samples were subjected to monotonic and fatigue loads in an ultra-short-life range, made of Inconel 718 super alloy. The samples displayed different behaviors as a result of different geometries that introduced varying levels of stress triaxiality and loading methods. The simulations used the Wierzbicki–Bai model, which took into account the influence of stress tensors and stress-deviator invariants on the behavior of the material. The difference in the behaviors of the smoothed and notched specimens subjected to tensile and fatigue loads were identified and described. The numerical results were qualitatively supported by the results of the experiments presented in the literature.

A Data-Driven Framework for Early-Stage Fatigue Damage Detection in Aluminum Alloys Using Ultrasonic Sensors

The paper presents a coupled machine learning and pattern recognition algorithm to enable early-stage fatigue damage detection in aerospace-grade aluminum alloys. U- and V-notched Al7075-T6 specimens are instrumented with a pair of ultrasonic sensors and, thereafter, tested on an MTS apparatus integrated with a confocal microscope and a digital microscope. The confocal microscope is focused on the notch root of the specimens, whereas the digital microscope is focused on the side of the notch. Two features, viz., the crack opening displacement (COD) and the crack length, are extracted during the tests in addition to the ultrasonic signal data. These signal data are analyzed using a machine learning framework that is built upon a symbolic time-series algorithm. This framework is interrogated for crack detection in the crack coalescence (CC) regime defined by COD of ~3 μm and detected through the confocal microscope. Additionally, the framework is probed in the crack propagation (CP) regime characterized by a crack length of ~0.2 mm and detected via the digital microscope. For the CC regime, training accuracies of 79.82% and 81.94% are achieved, whereas testing accuracies of 68.18% and 74.12% are observed for the U- and V-notched specimens, respectively. For the CP regime, overall training accuracies of 88.3% and 91.85% are observed, and accordingly, testing accuracies of 81.94% and 85.62% are obtained for the U- and V-notched specimens, respectively. The results show that a combined machine learning and pattern recognition algorithm enables robust and reliable fatigue damage detection in aerospace structural components.