Effect of operating parameters on functional fatigue characteristics of an Ni-Ti shape memory alloy on partial thermomechanical cycling

In this study, the influence of upper cycle temperature (maximum temperature in a cycle) and the magnitude of applied stress on the functional properties of an SMA during partial thermomechanical cycling has been studied. A near-equiatomic NiTi SMA was chosen and tested under different upper cycle temperatures (between martensite finish (Mf) and austenite finish (Af) temperatures) and stress level (below and above the yield strength of the martensite). The upper cycle temperature was varied by controlling the magnitude of the current supply. The results show that a raise in the upper cycle temperature causes the permanent strain to increase and also lowers the stability. However, decreasing the stress imposed to a value lower than the yield strength of the martensite improves cyclic stability. The upper cycle temperature was found to influence the crack nucleation, whereas the applied stress level the crack propagation during partial thermomechanical cycling of SMAs. Therefore, decreasing the upper cycle temperature as well as the magnitude of stress applied to lower than the yield stress of martensite have been found to be suitable strategies for increasing the lifespan of SMA-based actuators during partial thermomechanical cycling.

Strength and life estimation for assigning the useful life of wheelpairs of high-speed flat wagons

Aim. The most vital unit of railway rolling stock is a wheelpair, as a broken wheel or axle may have catastrophic consequences. Therefore, before the production of a highspeed flat wagon designed for operation at speeds of up to 140 km/h, which is unique for the 1520 mm gauge space, could commence, it was required to research the applicability of the standard wheelpair for high-speed movement. Ensuring the safe operation of a wheelpair involves compliance with the requirements that are to be confirmed by means of assessment of strength and durability parameters [1]. Product conformity assessment may be based on the requirements of standards, whose voluntary fulfilment ensures compliance with [1], or other documents. Methods. The paper describes the computational and experimental methods used for confirming the strength and estimating the life (durability) of wheelpair elements in the probabilistic setting. As experimental data, the authors used the results of full-scale bench testing of wheelpairs for fatigue using the method of rotational bending as it best approximates the loading conditions in operation. The results confirmed the endurance limits of the axle and wheel as parts of an assembled wheelpair. Using design analysis, the authors examined the stress-strain state of the wheelpair caused by installation and operational loads in various running modes. Results. The conducted studies confirmed the wheelpair’s compliance with the requirements of [1–3] in terms of safety factors of fatigue strength and endurance, which eliminates the possibility of hazardous situations in the course of high-speed flat wagon operation. The time to fatigue crack nucleation in wheelpair components was evaluated using the fatigue resistance figures of the parts and equivalent amplitudes of dynamic stress caused by operational loads. It appears that this assessment allows establishing – with the assumed probability of destruction – the assigned useful life of a wheelpair axle at 32 years, which corresponds to the assigned useful life of the flat wagon according to the combined criterion. Corresponding standards and regulations required for developing the container-carrying flat wagon are being updated and a new State Standard is being developed. Conclusion. The conducted conformity assessment established that the flat wagon wheelpair meets the safety requirements of [1] and ensures the absence of unacceptable risks associated with harm to life and health of people, animals and plants, the environment and property of individuals and companies in the course of flat wagon operation.

Crack nucleation at forging flaws studied by non-local peridynamics simulations

We present a computational study and framework that allows us to study and understand the crack nucleation process from forging flaws. Forging flaws may be present in large steel rotor components commonly used for rotating power generation equipment including gas turbines, electrical generators, and steam turbines. The service life of these components is often limited by crack nucleation and subsequent growth from such forging flaws, which frequently exhibit themselves as non-metallic oxide inclusions. The fatigue crack growth process can be described by established engineering fracture mechanics methods. However, the initial crack nucleation process from a forging flaw is challenging for traditional engineering methods to quantify as it depends on the details of the flaw, including flaw morphology. We adopt the peridynamics method to describe and study this crack nucleation process. For a specific industrial gas turbine rotor steel, we present how we integrate and fit commonly known base material property data such as elastic properties, yield strength, and S-N curves, as well as fatigue crack growth data into a peridynamic model. The obtained model is then utilized in a series of high-performance two-dimensional peridynamic simulations to study the crack nucleation process from forging flaws for ambient and elevated temperatures in a rectangular simulation cell specimen. The simulations reveal an initial local nucleation at multiple small oxide inclusions followed by micro-crack propagation, arrest, coalescence, and eventual emergence of a dominant micro-crack that governs the crack nucleation process. The dependence on temperature and density of oxide inclusions of both the details of the microscopic processes and cycles to crack nucleation is also observed. The results are compared with fatigue experiments performed with specimens containing forging flaws of the same rotor steel.

Finite element simulation of residual stresses and failure mechanism of plasma sprayed thermal barrier coatings considering real interface

In order to increase the efficiency of gas turbine engines, which are used for propulsion and electricity generation, the turbine inlet temperature (TIT) has to be as high as possible. Using Thermal Barrier Coatings (TBC) allows the metallic internal components to operate at elevated temperature near to its melting temperature. Thermally growing oxide induces cracks formation in the top coat that may lead to complete failure TBC due to spallation. This research aims at investigating the development of the stresses and critical cites that have possibility of crack nucleation due to thermal mismatch during operating cycle of a typical plasma sprayed TBC. A true finite element model was developed based on a scanning electron microscope image taking the advantage of a commercial finite element package (ABAQUS) and image processing techniques. The model including the effect of creep on all layers and plastic deformation of BC, TGO and substrate. The results show that unlike common unit cell models in literature, a better understanding can be achieved by having a model based in an SEM image that represents the real geometry.