Assessment of Ultra-High Cycle Fatigue Behavior of EN-GJL-250 Cast Iron Using Ultrasonic Fatigue Testing Machine

High cycle fatigue comprising up to 107 load cycles has been the subject of many studies, and the behavior of many materials was recorded adequately in this regime. However, many applications involve larger numbers of load cycles during the lifetime of machine components. In this ultra-high cycle regime, other failure mechanisms play, and the concept of a fatigue endurance limit (assumed for materials such as steel) is often an oversimplification of reality. When machine component design demands a high geometrical complexity, cast iron grades become interesting candidate materials. Grey cast iron is known for its low cost, high compressive strength, and good damping properties. However, the ultra-high cycle fatigue behavior of cast iron is poorly documented. The current work focuses on the ultra-high cycle fatigue behavior of EN-GJL-250 (GG25) grey cast iron by developing an ultrasonic (20 kHz) fatigue testing system. Moreover, the testing machine is instrumented to measure the temperature and the displacement of  the specimen, and to control the temperature. The high resonance frequency allowed to assess the  behavior of the cast iron of interest within a matter of days for ultra-high numbers of cycles, and repeat the tests to quantify the natural scatter in fatigue resistance.

Fatigue Strength of S275 Mild Steel under Cyclic Loading

This study examines the fatigue life of S275 mild steel at room temperature. Mechanical components can fail under cyclic loading during period of time, known as the fatigue phenomenon. In order to prevent fatigue induced failures, material behavior should be investigated to determine the endurance limit of the material for safe design and infinite life, thus leading to reducing the economic cost and loss in human lives. The fatigue behavior of S275 mild steel was studied and investigated. Specimens were prepared in accordance with ASTM E3-11, and fatigue tests of the specimen were conducted in accordance with ASTM E466-07 on a smooth plate, with a continuous radius between ends (hourglass-shaped plate). The method of fatigue testing was applied with constant load amplitude and constant frequency of 4 Hz with load ratio (Fully Reversal R= -1). Surface fractures of specimens were investigated using Scanning Electron Microscope (SEM). The experimental results were compared with the results of a Finite Element Analysis (FEA), using simulation software. The experiment results indicated that the endurance fatigue limit of S275 mild steel was 195.47 MPa.

Temperature Susceptibility of Multigrade Bitumen Asphalt and an Approach to Account for Temperature Variation through Deep Pavements

Multigrade bitumen asphalt is a quality asphalt product that is not utilised in many places globally. Multigrade bitumen is believed to be less sensitive to temperature, which gives it an advantage over conventional binders. Previous testing has shown that asphalt temperature changes greatly with depth, but currently the industry standard is to nominate a single temperature for design. For detailed design of asphalt roads, perhaps asphalt layers should be divided into nominal layer depths and different modulus and fatigue equations/values should be used to reflect the temperatures of each respective layer. A collaboration of previous laboratory testing conducted on multigrade bitumen asphalt beams under a range of temperatures and loading conditions was analysed. The samples tested included 0% or 15% recycled asphalt pavement (RAP) to determine what impact the recycled material has on the fatigue life and stiffness of the pavement. This paper investigated the temperature susceptibility of multigrade bitumen asphalt pavements compared to conventional binders by combining previous testing that included conducting a sweep of fatigue tests, developing complex modulus master curves for each mix and a study on how pavement temperature changes through pavement depth. This investigation found that the final design of the pavement is greatly affected by the nominated pavement temperature and respective material properties. This paper has outlined a potential revision to the current design approach for asphalt pavements and proposes that further investigation is needed into pavement temperature and its incorporation into design.

Laser Beam Micro-Drilling Effect on Ti-6Al-4V Titanium Alloy Sheet Properties

Laser beam micro-drilling (LBMD) is one of the most important non-contact machining processes of materials that are difficult to machine by means oeqf conventional machining methods used in various industries. The paper is focused on LBMD knock-down effect on Ti-6Al-4V (Grade 5) titanium alloy sheets properties. Two various process configurations were verified with a focus on laser damages in back-structure parts affected by the process. The effects of the LBMD on the material properties were assessed by means of tensile and fatigue tests and fracture surface analyses. Fatigue limit of LBMD configurations reached a significantly lower value between 15% and 30% of the static strength as compared to the reference raw material with 58% value. The farther back-structure configuration gives a two-fold fatigue life as compared to the closer LBMD configuration at a given stress applied.

The Mechanical Response of a Composite Propellant under Harsh Conditions

The aim of this paper is to study the mechanical properties of HTPB (Hydroxyl-terminated polybutadiene) composite propellant under harsh conditions. It describes two tests involving uniaxial tensile tests of various strain rates (ranging from 0.0005 s-1 to 1.5 s-1), temperatures (ranging from 223 K to 343 K) and high-cycle fatigue tests under low-temperature (223 K, frequencies were set at 50, 100, 150 Hz) using DMA (Dynamic Mechanical Analyzer). To highlight the effect of small pre-strain on fatigue properties of HTPB propellant, quasi-static stretching was carried out before fatigue loading, and uniaxial tensile tests at constant strain rates were successively applied. The results reveal that flow stress of propellant increases with reduction in temperature and rise in strain rate, and the strain rate-temperature equivalence relationship could be described by TTSP (time-temperature superposition principle) incorporating a modified WLF equation. Moreover, the rate of performance degradations and damage accumulation of propellant during fatigue tests increased with increasing strain amplitude and loading frequencies, while initial quasi-static loading has a negative effect on fatigue properties by comparing stress-strain relations after fatigue tests.

Finite Element Analysis of Ball-Joint Boots under Environmental and Endurance Tests

Ball joints support and guide certain automotive parts that move relative to the frame of the vehicle. Such ball joints are covered and protected from dust, mud, and other interfering materials by ball-joint boots made of rubber—a flexible and near-incompressible material. The boots may experience twisting and bending deformations because of the motion of the joint arm. Thus, environmental and endurance tests of ball-joint boots apply both bending and twisting deformations. In this study, environmental and endurance testing was simulated via the finite element method performed by using a commercial software package. The ranges of principal stress and principal strain values that are known to directly affect the fatigue lives of the parts were sought. By defining these ranges, the number of iterative tests and modifications of the materials and dimensions of the boot can be decreased. Therefore, instead of performing actual part tests, manufacturers can perform standard fatigue tests in trials of different materials by applying only the defined range of stress or strain values.

Influence of Raw Material Composition on Microstructure and Mechanical Properties of Nodular Cast Iron

The aim of this study is to evaluate the influence of raw material composition on the microstructure, mechanical and fatigue properties and micromechanisms of failure of nodular cast iron. In order to evaluate the influence of charge composition, the structural analysis, mechanical and fatigue tests and microfractographic analysis were carried out on specimens of ten melts with different charge compositions. The basic charge of individual melts was formed by different ratio of pig iron and steel scrap and by different additive for regulation of chemical composition (silicon carbide or ferrosilicon). The results show differences in mechanical and fatigue properties, which are connected with the microstructure. SiC additive positively influences microstructure. Consequently, mechanical and fatigue properties of nodular cast iron are improved, especially in the melts with higher ratio of steel scrap in the charge.

Thermal Fatigue Behavior of 400 Series Ferritic Stainless Steels

In this study, thermal fatigue properties of 400 series ferritic stainless steels have been evaluated in the temperature ranges of 200-800oC and 200-900oC. Systematic methods for control of temperatures within the predetermined range and measurement of load applied to specimens as a function of temperature during thermal cycles have been established. Thermal fatigue tests were conducted under fully constrained condition, where both ends of specimens were completely fixed. It has been revealed that load relaxation behavior at the temperatures of thermal cycle was closely related with the thermal fatigue property. Thermal fatigue resistance of 430J1L stainless steel is found to be superior to the other steels.

A Study on Fatigue Performance of Asphalt Using AMPT

Asphalt pavement itself is a mixture made up of mainly aggregates, binders, and fillers that acts as a composition used for pavement construction. An experimental program was setup to determine the fatigue performance test of Asphalt with three different grades of conventional binders. Asphalt specimen has achieved the maximum optimum bulk density and air voids with a consistent bulk density of 2.3 t/m3, with an air void of 5% ± 0.5, before loading into the Asphalt Mixture Performance Tested (AMPT) for fatigue test. The number of cycles is defined as the point where phase angle drops, which is caused by the formation of cracks due to the increasing micro cracks when asphalt is undergoing repeated cycles of loading. Thus, the data collected are analyzed using the drop of phase angle as failure criteria. Based in the data analyzed, it is evident that the fatigue life of asphalt lies on the grade of binder. The result obtained shows that all specimens do experience a drop in phase angle due to macro cracks in the asphalt specimen.

Study of the Green Composite Jute/Epoxy

Work presented is interested in the characterization of the quasistatic mechanical properties and in fatigue of a composite laminated in jute/epoxy. The natural fibers offer promising prospects thanks to their interesting specific properties, because of their low density, but also with their bio-deterioration. Several scientific studies highlighted the good mechanical resistance of the vegetable fiber composites reinforced, even after several recycling. Because of the environmental standards that become increasingly severe, one attends the emergence of eco-materials at the base of natural fibers such as flax, bamboo, hemp, sisal, jute. The fatigue tests on elementary vegetable fibers show an increase of about 60% of the rigidity of elementary fibers of hemp subjected to cyclic loadings. In this study, the test-tubes manufactured by the method infusion have sequences of stacking of 0/90° and ± 45° for the shearing and tensile tests. The quasistatic tests reveal a variability of the mechanical properties of about 8%. The tensile fatigue tests were carried out for levels of constraints equivalent to half of the ultimate values of the composite. Once the fatigue tests carried out for well-defined values of cycles, a series of static tests of traction type highlights the influence of the number of cycles on the quasi-static mechanical behavior of the laminate jute/epoxy.

Structure-Phase States of Al-Si Alloy after Electron-Beam Treatment and Multicycle Fatigue

Processing of Al-19.4Si alloy by high intensive electron beam has been carried out and multiple increases in fatigue life of the material have been revealed. Investigations of structure and surface modified layer destruction of Al-19.4Si alloy subjected to multicycle fatigue tests to fracture have been carried out by methods of scanning electron microscopy. The factors responsible for the increase of fatigue life of Al-19.4Si alloy have been revealed and analyzed.

Application of Flexi-Wall in Noise Barriers Renewal

This paper presents an experimental study on structural performance of an innovative noise barrier consisting of poly-block, light polyurethane foam (LPF) and polyurea. This wall system (flexi-wall) is intended to be employed as a vertical extension to existing sound barriers in an accelerated construction method. To aid in the wall design, several mechanical tests were conducted on LPF specimens and two full-scale walls were then fabricated employing the same LPF material. The full-scale walls were subjected to lateral loading in order to establish their lateral resistance. A cyclic fatigue test was also performed on a full-scale flexi-wall in order to evaluate the performance of the wall under a repetitive loading condition. The result of the experiments indicated the suitability of flexi-wall in accelerated construction and confirmed that the structural performance of the wall system under lateral loading is satisfactory for the sound barrier application. The experimental results were discussed and a preliminary design procedure for application of flexi-wall in sound barrier applications was also developed.

Viscoelastic Characterization of Bovine Trabecular Bone Samples

Knowledge of bone mechanical properties is important for bone substitutes design and fabrication, and more efficient prostheses development. The aim of this study is to characterize the viscoelastic behavior of bone specimens, through stress relaxation and fatigue tests performed to trabecular bone samples from bovine femoral heads. Relaxation tests consisted on preloading the samples at five different magnitudes and evaluate them for 1020 seconds, adjusting the results to a KWW mathematical model. Fatigue tests consisted of 700 load cycles and analyze their status at the end of the tests. As a conclusion we have that between relaxation stress and each preload there is linear relation and for samples with initial Young´s modulus greater than 1.5 GPa showed no effects due fatigue test loading cycles.

Structural Performance Evaluation of Segmented Wind Turbine Blade through Finite Element Simulation

Transportation of long turbine blades from one place to another is a difficult process. Hence a feasibility study of modularization of wind turbine blade was taken from structural standpoint through finite element analysis. Initially, a non-segmented blade is modeled and its structural behavior is evaluated to serve as reference. The resonant, static bending and fatigue tests are simulated in accordance with IEC61400-23 standard for comparison purpose. The non-segmented test blade is separated at suitable location based on trade off studies and the segments are joined with an innovative double strap bonded joint configuration. The adhesive joint is modeled by adopting cohesive zone modeling approach in ANSYS. The developed blade model is analyzed for its structural response through simulation. Performances of both the blades are found to be similar, which indicates that, efficient segmentation of the long blade is possible which facilitates easy transportation of the blades and on site reassembling. The location selected for segmentation and adopted joint configuration has resulted in an efficient segmented blade model which proves the methodology adopted for segmentation was quite effective. The developed segmented blade appears to be the viable alternative considering its structural response specifically in fatigue within considered assumptions.

Fatigue Tests of New Assembly Bolt Connections for Perspective Temporary Steel Railway Bridges

The paper deals with the problems of the actual behavior, failure mechanism and load-carrying capacity of the special bolt connection developed and intended for the assembly connections of truss main girders of perspective railway temporary steel bridges. Within the framework of this problem solution, several types of structural details of assembly joints have been considered as the conceptual structural design. Based on the preliminary evaluation of advantages or disadvantages of these ones, in principle two basic structural configurations – so-called “tooth” and “splice-plate” connections have been selected for the subsequent detailed investigation. This investigation is mainly based on the experimental verification of the actual behavior, strain and failure mechanism and corresponding strength of the connection, and on its numerical modeling using FEM. This paper is focused only on the cyclic loading (fatigue) tests results of “splice-plate” connections and their evaluation, which have already been finished. Simultaneously with the fatigue tests, the static loading tests have been realized too, but these ones, as well as FEM numerical modeling, are not the subject of this paper.

Thermal Fatigue Behavior of Austenitic Stainless Steels

Continually increasing working temperature and growing need for greater efficiency and reliability of automotive exhaust require systematic investigation into the thermal fatigue properties especially of high temperature stainless steels. In this study, thermal fatigue properties of 300 series austenitic stainless steels have been evaluated in the temperature ranges of 200-800oC and 200-900oC. Systematic methods for control of temperatures within the predetermined range and measurement of load applied to specimens as a function of temperature during thermal cycles have been established. Thermal fatigue tests were conducted under fully constrained condition, where both ends of specimens were completely fixed. Load relaxation behavior at the temperatures of thermal cycle was closely related with the thermal fatigue property.

On the Fatigue Behavior of a Triphasic Composite

This paper presents the results of an experimental characterization of a glass fibre-epoxy composite. The behavior of the traditional two-phase composite has been compared with the one of a new three-phase composite where the epoxy matrix was modified by addition of a 3% weight fraction of montmorillonite nano-particles. Two different types of nano-clays, Cloisite® 30B and RXG7000, produced by Southern Clay Products Inc., have been considered. Three-point bending tests, both monotonic and cyclic, were carried out. A strong reduction of the ultimate flexural strength upon nano-modification has been observed in quasi-static tests. Fatigue tests yielded a smaller strength loss. In both quasi-static and fatigue tests a more pronounced tendency to delamination has been noticed in three-phase composites, especially in the case of 30B nano-clay, with respect to the standard two-phase glass fiber composite.

Properties of SMA Mixtures Containing Waste Polyethylene Terephthalate

Utilization of waste material in asphalt pavement would be beneficial in order to find an alternative solution to increase service life of asphalt pavement and reduce environmental pollution as well. One of these waste materials is Polyethylene Terephthalate (PET) which is a type of polyester material and is produced in a large extent. This research program is investigating the effects of adding waste PET particles into the asphalt mixture with a maximum size of 2.36 mm. Different percentages of PET were added into the mixture during dry process. Gap-graded mixture (SMA 14) and PG 80-100 asphalt binder have been used for this study. To evaluate PET reinforced asphalt mixture different laboratory investigations have been conducted on specimens. Marshall Stability test was carried out. Besides, stiffness modulus test and indirect tensile fatigue test were conducted on specimens at optimum asphalt content. It was observed that in many cases PET reinforced SMA mixture had better mechanical properties in comparison with control mixture.

Fretting Fatigue behavior of Bolted Single Lap Joints of Aluminum Alloys

In this paper, the effect of bolt clamping force on the fatigue behavior of bolted single lap joints of aluminum alloy 2024- T3 have been studied using numerical finite element method. To do so, a three dimensional model according to the bolted single lap joint has been created and numerical analysis has been carried out using finite element based package. Then the stress distribution and also the slip amplitudes have been calculated in the critical regions and the outcome have been compared with the available experimental fatigue tests results. The numerical results show that in low applied clamping force, the fatigue failure of the specimens occur around the stress concentration location (the bolted hole edge) due to the tensile stresses and thus fatigue crack propagation, but with increase of the clamping force, the fatigue life increases and the cracks nucleate and propagate far from the hole edge because of fretting fatigue. In other words, with the further increase of clamping force value of the joint, the fatigue life reduces due to occurrence of the fretting fatigue in the critical location where the slip amplitude is within its critical occurs earlier.

The Effect of Maximum Strain on Fatigue Life Prediction for Natural Rubber Material

Fatigue life prediction and evaluation are the key technologies to assure the safety and reliability of automotive rubber components. The objective of this study is to develop the fatigue analysis process for vulcanized rubber components, which is applicable to predict fatigue life at initial product design step. Fatigue life prediction methodology of vulcanized natural rubber was proposed by incorporating the finite element analysis and fatigue damage parameter of maximum strain appearing at the critical location determined from fatigue test. In order to develop an appropriate fatigue damage parameter of the rubber material, a series of displacement controlled fatigue test was conducted using threedimensional dumbbell specimen with different levels of mean displacement. It was shown that the maximum strain was a proper damage parameter, taking the mean displacement effects into account. Nonlinear finite element analyses of three-dimensional dumbbell specimens were performed based on a hyper-elastic material model determined from the uni-axial tension, equi-biaxial tension and planar test. Fatigue analysis procedure employed in this study could be used approximately for the fatigue design.