Abstract: This paper studies a failure case of a fuel pressure supply tube from an aircraft engine. Multiple fracture cases of the fuel pressure control tube from aircraft engines have been reported. The studied set was composed by the mentioned tube, a welded connecting pipe, where the fracture has been produced, and a union nut. The fracture has been produced in one of the most critical zones of the tube, in a region next to the supporting body of the union nut to the connector. The tube material was X6CrNiTi18-10, an austenitic stainless steel. Chemical composition was determined using an X-Ray fluorescence spectrometer (XRF) and combustion equipment. Furthermore, the material was characterized mechanically, by a hardness test, and microstructurally using a stereo microscope and an optical microscope. The results confirmed that the material was within specifications. To determine the macrofractographic features, a visual examination and an observation using a stereo microscope of the tube fracture surface were carried out. The results revealed a tube plastic macrodeformation, surface damaged and signs of a possible corrosion process. Fracture surface was also inspected by scanning electron microscopy (FE-SEM), equipped with an energy-dispersive X-ray microanalysis system (EDX), to determine the microfractographic features in order to find out the failure mechanism involved in the fracture. Fatigue striations, which are typical from a progressive fracture by a fatigue mechanism, were observed. The origin of the fracture was placed in defects located on the outer wall of the tube, leading to a final overload fracture.
Abstract: This study focuses on the effect of the addition of magnesium (Mg) and silver (Ag) on the mechanical properties of aluminum based alloys. The alloying elements will be added at different levels using the factorial design of experiments of 22; the two factors are Mg and Ag at two levels of concentration. The superior mechanical properties of the produced Al-Cu-Mg-Ag alloys after aging will be resulted from a unique type of precipitation named as Ω-phase. The formed precipitate enhanced the tensile strength and thermal stability. This paper further investigated the microstructure and mechanical properties of as cast Al–Cu–Mg–Ag alloys after being complete homogenized treatment at 520 °C for 8 hours followed by isothermally age hardening process at 190 °C for different periods of time. The homogenization at 520 °C for 8 hours was selected based on homogenization study at various temperatures and times. The alloys’ microstructures were studied by using optical microscopy (OM). In addition to that, the fracture surface investigation was performed using a scanning electronic microscope (SEM). Studying the microstructure of aged Al-Cu-Mg-Ag alloys reveal that the grains are equiaxed with an average grain size of about 50 µm. A detailed fractography study for fractured surface of the aged alloys exhibited a mixed fracture whereby the random fracture suggested crack propagation along the grain boundaries while the dimples indicated that the fracture was ductile. The present result has shown that alloy 5 has the highest hardness values and the best mechanical behaviors.
Abstract: 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.
Abstract: The research work reported here was aimed at investigating the feasibility of joining high-porosity stainless steel discs and wrought iron bars by friction welding. The sound friction-welded joints were then subjected to a metallurgical investigation and an analysis of failure resulting from tensile loading. Discs having 50 mm diameter and 10 mm thickness were produced by loose sintering of stainless steel powder at a temperature of 1350 oC in an argon atmosphere for one hour. Minor machining was then carried out to control the dimensions of the discs, and the density of each disc could then be determined. The level of porosity was calculated and was found to be about 40% in all of those discs. Solid wrought iron bars were also machined to facilitate tensile testing of the joints produced by friction welding. Using our previously gained experience, the porous stainless steel disc and the wrought iron tube were successfully friction welded. SEM was employed to examine the fracture surface after a tensile test of the joint in order to determine the type of failure. It revealed that the failure did not occur in the joint, but rather in the in the porous metal in the area adjacent to the joint. The load carrying capacity was actually determined by the strength of the porous metal and not by that of the welded joint. Macroscopic and microscopic metallographic examinations were also performed and showed that the welded joint involved a dense heat-affected zone where the porous metal underwent densification at elevated temperature, explaining and supporting the findings of the SEM study.
Abstract: Rice husk and kenaf filled with calcium carbonate
(CaCO3) and high density polyethylene (HDPE) composite were
prepared separately using twin-screw extruder at 50rpm. Different
filler loading up to 30 parts of rice husk particulate and kenaf fiber
were mixed with the fixed 30% amount of CaCO3 mineral filler to
produce rice husk/CaCO3/HDPE and kenaf/CaCO3/HDPE hybrid
composites. In this study, the effects of natural fiber for both rice
husk and kenaf in CaCO3/HDPE composite on physical, mechanical
and morphology properties were investigated. Field Emission
Scanning Microscope (FeSEM) was used to investigate the impact
fracture surfaces of the hybrid composite. The property analyses
showed that water absorption increased with the presence of kenaf
and rice husk fillers. Natural fibers in composite significantly
influence water absorption properties due to natural characters of
fibers which contain cellulose, hemicellulose and lignin structures.
The result showed that 10% of additional natural fibers into hybrid
composite had caused decreased flexural strength, however additional
of high natural fiber (>10%) filler loading has proved to increase its
flexural strength.
Abstract: The influence of three different types of halloysite
nanotubes (HNTs) with different dimensions, namely as camel lake
(CLA), Jarrahdale (JA) and Matauri Bay (MB), on their reinforcing
ability of ethylene propylene dine monomer (EPDM) were
investigated by varying the HNTs loading (from 0-15 phr).
Mechanical properties of the nanocomposites improved with addition
of all three HNTs, but CLA based nanocomposites exhibited a
significant enhancement compared to the other HNTs. For instance,
tensile properties of EPDM nanocomposites increased by 120%,
256% and 340% for MB, JA and CLA, respectively, with addition of
15 phr of HNTs. This could be due to the higher aspect ratio and
higher surface area of CLA compared to others. Scanning electron
microscopy (SEM) of nanocomposites at 15 phr of HNT loadings
showed low amounts of pulled-out nanotubes which confirmed the
presence of more embedded nanotubes inside the EPDM matrix, as
well as aggregates within the fracture surface of EPDM/HNT
nanocomposites
Abstract: Three dimensional non-Interlaced carbon fibre
reinforced silicon carbide (3-D-Cf/SiC) composites with pyrocarbon
interphase were fabricated using isothermal chemical vapor
infiltration (ICVI) combined with polymer impregnation pyrolysis
(PIP) process. Polysilazane (PSZ) is used as a preceramic polymer to
obtain silicon carbide matrix. Thermo gravimetric analysis (TGA),
Infrared spectroscopic analysis (IR) and X-ray diffraction (XRD)
analysis were carried out on PSZ pyrolysed at different temperatures
to understand the pyrolysis and obtaining the optimum pyrolysing
condition to yield β-SiC phase. The density of the composites was
1.94 g cm-3 after the 3-D carbon preform was SiC infiltrated for 280 h
with one intermediate polysilazane pre-ceramic PIP process.
Mechanical properties of the composite materials were investigated
under tensile, flexural, shear and impact loading. The values of
tensile strength were 200 MPa at room temperature (RT) and 195
MPa at 500°C in air. The average RT flexural strength was 243 MPa.
The lower flexural strength of these composites is because of the
porosity. The fracture toughness obtained from single edge notched
beam (SENB) technique was 39 MPa.m1/2. The work of fracture
obtained from the load-displacement curve of SENB test was 22.8
kJ.m-2. The composites exhibited excellent impact resistance and the
dynamic fracture toughness of 44.8 kJ.m-2 is achieved as determined
from instrumented Charpy impact test. The shear strength of the
composite was 93 MPa, which is significantly higher compared 2-D
Cf/SiC composites. Microstructure evaluation of fracture surfaces
revealed the signatures of fracture processes and showed good
support for the higher toughness obtained.
Abstract: The impact deformation and fracture behaviour of cobalt-based Haynes 188 superalloy are investigated by means of a split Hopkinson pressure bar. Impact tests are performed at strain rates ranging from 1×103 s-1 to 5×103 s-1 and temperatures between 25°C and 800°C. The experimental results indicate that the flow response and fracture characteristics of cobalt-based Haynes 188 superalloy are significantly dependent on the strain rate and temperature. The flow stress, work hardening rate and strain rate sensitivity all increase with increasing strain rate or decreasing temperature. It is shown that the impact response of the Haynes 188 specimens is adequately described by the Zerilli-Armstrong fcc model. The fracture analysis results indicate that the Haynes 188 specimens fail predominantly as the result of intensive localised shearing. Furthermore, it is shown that the flow localisation effect leads to the formation of adiabatic shear bands. The fracture surfaces of the deformed Haynes 188 specimens are characterised by dimple- and / or cleavage-like structure with knobby features. The knobby features are thought to be the result of a rise in the local temperature to a value greater than the melting point.
Abstract: Shear testing is one of the most complex testing areas where available methods and specimen geometries are different from each other. Therefore, a modified shear test specimen (MSTS) combining the simple uniaxial test with a zone of interest (ZOI) is tested which gives almost the pure shear. In this study, material parameters of polypropylene (PP) and high density polyethylene (HDPE) are first measured by tensile tests with a dogbone shaped specimen. These parameters are then used as an input for the finite element analysis. Secondly, a specially designed specimen (MSTS) is used to perform the shear stress tests in a tensile testing machine to get the results in terms of forces and extension, crack initiation etc. Scanning Electron Microscopy (SEM) is also performed on the shear fracture surface to find material behavior. These experiments are then simulated by finite element method and compared with the experimental results in order to confirm the simulation model. Shear stress state is inspected to find the usability of the proposed shear specimen. Finally, a geometry correction factor can be established for these two materials in this specific loading and geometry with notch using Linear Elastic Fracture Mechanics (LEFM). By these results, strain energy of shear failure and stress intensity factor (SIF) of shear of these two polymers are discussed in the special application of the screw cap opening of the medical or food packages with a temper evidence safety solution.
Abstract: The incidence of mechanical fracture of an
automobile piston rings prompted development of fracture analysis
method on this case. The three rings (two compression rings and one
oil ring) were smashed into several parts during the power-test (after
manufacturing the engine) causing piston and liner to be damaged.
The radial and oblique cracking happened on the failed piston rings.
The aim of the fracture mechanics simulations presented in this paper
was the calculation of particular effective fracture mechanics
parameters, such as J-integrals and stress intensity factors. Crack
propagation angles were calculated as well. Two-dimensional
fracture analysis of the first compression ring has been developed in
this paper using ABAQUS CAE6.5-1 software. Moreover, SEM
fractography was developed on fracture surfaces and is discussed in
this paper. Results of numerical calculations constitute the basis for
further research on real object.
Abstract: Scatter behavior of fatigue life in die-cast AM60B
alloy was investigated. For comparison, those in rolled AM60B alloy
and die-cast A365-T5 aluminum alloy were also studied. Scatter
behavior of pore size was also investigated to discuss dominant
factors for fatigue life scatter in die-cast materials. Three-parameter
Weibull function was suitable to explain the scatter behavior of both
fatigue life and pore size. The scatter of fatigue life in die-cast
AM60B alloy was almost comparable to that in die-cast A365-T5
alloy, while it was significantly large compared to that in the rolled
AM60B alloy. Scatter behavior of pore size observed at fracture
nucleation site on the fracture surface was comparable to that
observed on the specimen cross-section and also to that of fatigue
life. Therefore, the dominant factor for large scatter of fatigue life in
die-cast alloys would be the large scatter of pore size. This
speculation was confirmed by the fracture mechanics fatigue life
prediction, where the pore observed at fatigue crack nucleation site
was assumed as the pre-existing crack.
Abstract: This paper reports the tensile fracture location
characterizations of dissimilar friction stir welds between 5754
aluminium alloy and C11000 copper. The welds were produced using
three shoulder diameter tools; namely, 15, 18 and 25 mm by varying
the process parameters. The rotational speeds considered were 600,
950 and 1200 rpm while the feed rates employed were 50, 150 and
300 mm/min to represent the low, medium and high settings
respectively. The tensile fracture locations were evaluated using the
optical microscope to identify the fracture locations and were
characterized. It was observed that 70% of the tensile samples failed
in the Thermo Mechanically Affected Zone (TMAZ) of copper at the
weld joints. Further evaluation of the fracture surfaces of the pulled
tensile samples revealed that welds with low Ultimate Tensile
Strength either have defects or intermetallics present at their joint
interfaces.
Abstract: Fracture process in mechanically loaded steel fiber
reinforced high-strength (SFRHSC) concrete is characterized by
fibers bridging the crack providing resistance to its opening.
Structural SFRHSC fracture model was created; material fracture
process was modeled, based on single fiber pull-out laws, which were
determined experimentally (for straight fibers, fibers with end hooks
(Dramix), and corrugated fibers (Tabix)) as well as obtained
numerically ( using FEM simulations). For this purpose experimental
program was realized and pull-out force versus pull-out fiber length
was obtained (for fibers embedded into concrete at different depth
and under different angle). Model predictions were validated by
15x15x60cm prisms 4 point bending tests. Fracture surfaces analysis
was realized for broken prisms with the goal to improve elaborated
model assumptions. Optimal SFRHSC structures were recognized.