Institute of Fundamental Technological Research

Metal matrix composites (MMCs) with aluminium alloy AA2124 matrix reinforced with 17 and 25% of SiC were investigated. Symmetric tension-compression fatigue tests at ambient temperature and tensile creep tests at elevated temperature were carried out. Specimens were subjected to fatigue or creep loading conditions. Tests were stopped after given number of cycles or strain values respectively. Electronic Speckle Pattern Interferometry (ESPI) was used in order to detect damage under fatigue and creep conditions. Strain fields were observed on specimens’ surfaces to localise strain concentrations that would indicate areas of damage development.

Creep, Damage, ESPI (Electronic Speckle Pattern Interferometry), Fatigue, MMC (Metal Matrix Composite)

The results of comparative examinations of mechanical behaviour during fatigue loads and microstructure assessment before and after fatigue tests were presented. Composites of aluminium matrix and SiC reinforcement manufactured using the KoBo method were investigated. The combinations of two kinds of fatigue damage mechanisms were observed. The first one governed by cyclic plasticity and related to inelastic strain amplitude changes and the second one expressed in a form of ratcheting based on changes in mean inelastic strain. The higher SiC content the less influence of the fatigue damage mechanisms on material behaviour was observed. Attempts have been made to evaluate an appropriate fatigue damage parameter. However, it still needs further improvements.

fatigue, damage, metal matrix composites, microstructure

Strength and durability of thin-walled structures are usually calculated with the use of computer simulations. To perform such simulations using Finite Element Method, characteristics of a material subjected to monotonic tension or compression and tension-compression cyclic loading are necessary. Experimental determination of such kind of characteristics is usually performed on specimens cut out from a metal or composite thin sheet. Problems associated with testing on flat specimens under large deformation are discussed in this paper. A new design of fixture proposed by the authors for this kind of testing is shortly described. The results of investigations carried out on brass using the new fixture for flat specimens testing are also presented.

fixture, large deformations, tension-compression tests, thin metal sheet

Two grades of structural steel were subjected to fully reversible, constant stress amplitude cyclic loading. The local strain response of the material was measured and recorded during the test, with the applied testing technique enabling the monitoring of hysteresis loop variation for the narrowest cross-section of the hourglass specimen. Changes in hysteresis loop width, representing the local inelastic response of the material, were recorded in order to monitor the density of structural imperfections. Material ratcheting behaviour was observed as changes in the mean strain for selected load cycles. Ratcheting was attributed to local deformation of the material in the vicinity of imperfections such as voids or inclusions, as well as deformation induced by the propagation of microcracks. Definitions of a damage indicator parameter and damage parameter were proposed. The fatigue behaviour of the two investigated grades of steel was finally illustrated in the form of damage curves for different stress amplitudes and for undamaged and fatigue pre-damaged material.

Determination of cyclic properties of a material used for many engineering structures, e.g. airframes, requires preparation of specimens from two-dimensional, shell structures. A specimen must be cut out from the structure component in the way allowing application of a load corresponding to that reflecting service cases. In order to fulfil this requirement, tension–compression testing of the flat specimen is necessary to obtain credible data. Problems associated with such kind of testing are discussed in this paper. In the first part, an extensive review of the anti-buckling fixtures developed up to now is given. Several representative solutions are discussed, with special emphasis on the technique limitations. In the second part of the paper, detailed description of the proposed design is given. Finally, the results of preliminary tests carried out using new fixture to mount the flat specimens cut from steel sheets are presented. Application of the proposed testing technique allowed tension–compression tests to be performed at the displacement amplitude within the range ±5 mm what corresponds to the maximum strain amplitude of ±0.4 for the specimen gauge length to be equal 12.5 mm. Taking into account all data captured by means of new fixture, one can conclude that the technique is promising with respect to providing data for modelling of cyclic deformation behaviour for shell structures.

buckling, cyclic loading, fixture, thin sheets

In response to engineering needs of measuring moderate or large strains in metallic structures’ progress in resistance strain gages, technology resulted in widening the measurement range of this type of sensors to a range of 10–15%. For precision strain measurement applications, especially when a considerable number of measurement points are involved, single strain gage sensors are commonly used in quarter Wheatstone bridge configurations. Extension of measurement range to moderate strains requires taking into account inherent nonlinearities in signal transfer functions of the elements present in measurement chain. This work discusses in detail the most important ones, that is resistive gage sensor and quarter bridge measurement configuration nonlinearities to indicate that they are of the same order for moderate strains. Quite straightforward, shunt calibration procedure, taking into account these nonlinearities, is delivered or proposed enabling elimination of systematic errors. Thus, optimum accuracy of strain measurements matching the characteristics of components of strain measurement system can be conveniently achieved upon following simple steps. Inverse hyperbolic tangent—ϵLn =tanh−1(2 ∙e0/Eex)—linking scalar logarithmic strain and bridge reduced output voltage is shown to be a transfer function of strain measurement system with gage sensor in quarter bridge configuration for moderate or large strains.

Experimental Data Acquisition, Data Processing, Nonlinear Transfer Functions, Nonlinear Signal Conditioning, Experimental Strain/Stress Analysis, Accurate Finite Strain Measurements, Resistance Strain Gages, Nonlinear Sensors, Small/Technical Strain, Logarithmic/Natural Strain, Moderate Strains, Quarter Bridge Configuration, Wheatstone Bridge Circuits, Shunt Calibration, Scaling Amplifier Gain

Changes in the mechanical characteristics of the structural steel because of fatigue damage accumulation are investigated in this article. Cyclic loading was performed in a complex stress state. Tubular specimens were loaded by axial force and torque, with loading performed along proportional and non-proportional paths in the strain space. Material characteristics in the form of the stress–strain curve and yield surface were determined in the ‘as received’ state and after cyclic loading. It was found that accumulation of the fatigue damage because of cyclic loading in a complex stress state along proportional and non-proportional paths in the strain space is manifested by the increase in inelastic response. The rate of damage was found to be higher for non-proportional (circular) loading paths than that for proportional loading with the same strain amplitude.

complex stress state, damage accumulation, fatigue, strain space, yield surface

Monitorowanie zjawisk związanych ze zmęczeniem materiałów jako procesu inicjowanego lokalnie wymaga całopolowych obserwacji deformacji zachodzących pod wpływem obciążeń zmęczeniowych. Metoda elektronicznej interferometrii plamkowej (ESPI) pozwala z dużą precyzją (przy zachowaniu stabilności układu pomiarowego) określić rozkład odkształceń na powierzchni próbki i tym samym wskazać miejsca koncentracji naprężeń wywołanych karbem (strukturalnym, geometrycznym). Możliwa jest także ocena rozwoju tych deformacji w kolejnych cyklach zmęczenia aż do utworzenia pęknięcia i dekohezji próbki. Bieżący pomiar odkształceń w strefie ich lokalizacji pozwala na ilościową ocenę dynamiki rozwoju uszkodzenia zmęczeniowego w badanym materiale.

An influence of the chemical composition, porosity and ageing on mechanical behaviour of light, multifunctional aluminium alloys (AlSi8Cu3 and AlSi7MgCu0.5) subjected to creep and low cycle fatigue (LCF) was investigated. The materials were tested to verify their applicability as the cylinder heads in car engines. During creep tests, a strain response of the materials was observed under a range of the step-increased stresses and different temperatures. The LCF tests were carried out under strain control in three blocks of 100 cycles each with a constant strain amplitude. The results of creep and LCF tests were analysed with regard to chemical composition, type of porosity and ageing of the materials tested. An influence of porosity on the creep resistance and lifetime was considered. The results of the LCF tests were compared for the materials in the as-received state and after ageing. An experimental evaluation of cyclic behaviour because of the LCF was carried out to check whether the hardening or softening effects can be observed in the materials. Taking into account the various history of loading, a stress response of the materials was investigated.

creep, cylinder heads, fatigue, light alloys

The experimental identification of fatigue damage mechanisms and evaluation of their development rate, based on changes in material respond on cycle loading, has been presented in the work. The research has been conducted on hyper-eutectic cast alloy AlSi8Cu3. The microstructure and fracture analyses were performed. The high cycle fatigue tests were conducted with frequency of 20 Hz under constant nominal stress amplitude with monitoring the strain response of material during the test. The ratcheting was found as the main mechanism of the fatigue damage. It was established that the linear fatigue accumulation law should not be used for fatigue life prediction in case of the tested cast aluminum alloy

Cast aluminum alloy, Fatigue test, Fatigue damage

The paper presents experimental investigations of two light aluminium alloys (AlSi8Cu3 and AlSi7MgCu0 5) under loading conditions leading to the creep or fatigue processes. During the creep process, the strains were measured under selected tensile stresses and temperatures. An influence of a step loading during creep, at elevated temperature, on steady creep rate and a course of creep curve, was investigated. Moreover, an effect of porosity degree on creep of both aluminium alloys was also analysed. An influence of aging process at the elevated temperature was experimentally evaluated. Fatigue behaviour of materials was checked under strain control using cylindrical samples. The results of LCF tests were analysed for the materials subjected to three-stage sequence of loading at elevated temperature. A resistance to creep and fatigue processes of the AlSi8Cu3 was weaker than that obtained in the case of the AlSi7MgCu0 5.

Creep, Fatigue, Sequence loading, Aluminium alloys

W pracy dokonano oceny stopnia uszkodzenia eksploatacyjnego materiału próbek z elementów rurociągów pary wtórnie przegrzanej po 100 000 godzin pracy na podstawie zmian właściwości zmęczeniowych oraz zmian mikrostruktury. Dokonano testów zmęczenia wysokocyklowego dla zmiennej amplitudy naprężenia z uwzględnieniem rozwoju odkształceńśrednich i niesprężystych. Na tej podstawie opracowano parametry opisujące stopień zniszczenia materiału pod wpływem obciążeń cyklicznych dla próbek w stanie przed i po eksploatacji. Analiza porównawcza wyznaczonych współczynników pozwala oszacować procentowy stopień degradacji materiału próbek eksploatowanych. Wykonano badania metalograficzne z wykorzystaniem Elektronowej Mikroskopii Skaningowej, na podstawie których scharakteryzowano mikrostrukturalne zmiany wynikające z długotrwałej pracy w warunkach eksploatacji rurociągów energetycznych.

A consolidation of powders using the KOBO method at elevated temperature was elaborated for production of Al/SiC metal matrix composite (MMC). The observations of the mean strain and inelastic strain range during the force controlled high cycle fatigue (HCF) tests identified the ratcheting mechanism combined with mechanism characterized by cyclic plasticity. Damage parameters were calculated on the basis of strain signal acquisition during fatigue tests. Fatigue properties, creep resistance and life time of Al/SiC MMC were gradually improved with the increase of the SiC particles content. The microstructural observations of the material before and after tests were also performed.

MMC, KOBO method, fatigue, creep, monotonic loading, microstructure, damage

The AlSi8Cu3 and AlSi7MgCu0.5 cast aluminium alloy s of different composition and heat treatment were investigated to verify their applicability as cylinder heads in the car engines [1]. Creep tests under the step-increased stresses at different temperatures, and low cycle fatigue (LCF) tests for a range of strain amplitudes and temperatures were carried out. The results exhibit a significant influence of the heat treatment on the mechanical properties of the AlSi8Cu3 and AlSi7MgCu0.5. An interesting fact is that the properties strongly depend on the type of quenching. Lower creep resistance (higher strain rates) and lower stress response during fatigue tests were observed for the air quenched materials in comparison to those in the water quenched. Cyclic hardening/softening were also observed during the LCF tests due to the heat treatment applied. The mechanical properties determined during the tests can be used to identify new constitutive equations and to verify existing numerical models.

creep, low cycle fatigue, aluminum alloys, heat treatment

The paper presents experimental results of creep and low cycle fatigue (LCF) tests carried out on the as-received cast aluminium alloys with different chemical composition and porosity. The test programmes contain creep investigations under step-increased stresses at different temperatures, and cyclic plasticity under different strain amplitudes and temperatures

creep, low cycle fatigue, aluminium alloys

In this article the review of the original research is given in. which are described the experimental investigations of fatigue fracture under combined stresses. The papers have been ordered according to shape of the specimens: complex shape specimens, thick-walled specimens, thin-walled specimens. Each group of papers is presented in the chronological order. Equations of the fatigue conditions mentioned in papers are given.

The complete solutions for the plastic bending of deeply notched bars are presented for certain configurations of the notch. Extensions of the stress fields into the rigid regions have been obtained by superimposing two fields of the type given by J.F.W. Bishop for axially loaded notched bars, or one such a field, on an uniaxially tensioned (or compressed) strip. For other shapes of the notch the method breaks down; it then gives lower bounds on the yield moment.

The plastic incipient flow of V-notched axially symmetric bars with different slope of the two generators is considered using theTresca yield criterion and associated flow rule. The experimental results show good agreement with theoretical solutions.

Yield Criterion, Flow Rule

Theoretical and experimental results are presented for plastic flow of axially symmetric notched bars. The slip-line fields have been calculated numerically using the Shield theory of axially symmetric plastic flow. The load factors obtained from the theoretical solutions differ only slightly from those for plane strain conditions. Two sets of specimens were investigated in order to obtain the actual load factors for V-shaped and rounded notches. The agreement between the theory and experimental results is satisfactory. In the last series of experiments the influence of the diameter of the bar outside the notch was investigated and later compared with the theoretically estimated value of that diameter.

Modern automobile and airplane structures made of sheet metals or composites require usage of thinner and stronger materials. On the other hand, manufacturers are trying to reduce production costs by shortening the fabrication processes and by application of computed simulation for forming operation. Therefore, it is necessary to better understand and more accurately investigate deformation behaviour of sheet alloys. Testing of flat specimens under compression and cyclic tension-compression within large deformation procures a lot of problems. One of them is the buckling phenomenon. A new version of the device mounted in a standard testing machine was developed and geometry of the specimen for validation of the device was proposed. Specimens of DP690 steel with nominal thickness equal to 1.6 mm were investigated at ambient temperature. Tension-compression cyclic tests within a strain range ± 0.04 were executed starting in tension direction. It is shown that the results are repeatable.

Buckling, cyclic loading, fixture, thin sheets

Strength and durability of thin-walled structures are usually calculated with the use of computer simulations. To perform such simulations using Finite Element Method the characteristics of a material subjected to monotonic tension/or compression and tension-compression cyclic loading are necessary for example. Experimental determination of such kind of characteristics is usually performed on specimens cut out from metal or composite thin sheet. Problems associated with material testing on flat specimens under large deformation are discussed in detail by this paper. In the first part, a short review of the antibuckling fixtures developed up to now is given. Several representative solutions including the applied design are discussed, with special emphasis on the technique limitations. In the second part, the results of investigations carried out on steel and brass using the new fixture for the flat specimens testing are presented.

fixture, large deformations, tension-compression tests, thin metal sheet

Fatigue tests of AA2124 based metal matrix composites (MMCs) with SiC particles reinforcement were carriedout. The MMCs were manufactured using powder metallurgy. Hysteresis loops were observed during subsequent cycles. Cyclic plasticity and ratcheting were identified as main fatigue damage mechanisms. Inelastic strain amplitude and mean inelastic strain were calculated to be used as fatigue damage indicators. Ultrasonic measurements during fatigue tests were performed but they did not allow to detect damage during fatigue test.

metal matrix composites, fatigue, damage

W pracy dokonano analizy wskaźników rozwoju uszkodzenia zmęczeniowego, opracowanych w oparciu o wyniki testów zmęczeniowych próbek ze stali P91, w stanie dostawy i po 80 000 godzin eksploatacji w warunkach pracy instalacji energetycznej. Wykonano badania zmęczeniowe dla dwóch typów próbek i wyznaczono funkcje zmiany parametrów uszkodzeń w zależności od liczby cykli przy różnych amplitudach naprężenia. Uzyskane wyniki wykorzystano do wyznaczenia klasycznej charakterystyki zmęczeniowej, ale również do wyznaczenia ewolucji uszkodzeń w zależności od liczby cykli. Wyniki wskazały na możliwość jej opisania przy pomocy dwóch makroskopowych wskaźników rozwoju zmęczenia. Pierwszy z nich to średnie odkształcenie w kolejnych cyklach obciążenia przy stałej amplitudzie naprężenia. Drugim, jest odkształcenie niesprężyste w cyklu obrazujące szerokość pętli histerezy w kolejnych fazach obciążenia ostałej amplitudzie naprężenia. Rozwój uszkodzenia wstali P91poddanej obciążeniom zmęczeniowym opisano stosując kombinację wyżej wymienionych wskaźników

badania zmęczeniowe, ewolucja uszkodzeń, wskaźniki uszkodzenia

Optimization of sheet metal forming processes requires a very good knowledge of material forming ability. During the forming of industrial parts, very complex strain paths are usually observed and can affect the formability of the sheet. Therefore, it is necessary to better understand and more accurately investigate deformation behaviour of sheet alloys. It should be noted that material testing of flat specimens under compression within a large deformation range procures many difficulties, and the buckling phenomenon seems to be the most im-portant. This paper shows the results of tension-compression tests carried out on specimens made of ultralight magnesium alloys AZ31B with nominal thickness equal to 1 mm using the anti-buckling fixture to avoid buckling problem.

Bauschinger effect, cyclic loading, buckling, fixture, thin sheet

Problems associated with material testing on flat specimens under large deformation due to compression or cyclic tension-compression are discussed. A short review of the anti-buckling fixtures developed up to now is given with special emphasis on the new fixture elaborated at the Institute of Fundamental Technological Research in Poland.

Problems associated with material testing on flat specimens under large deformation are discussed in this paper. An extensive review of the anti - buckling fixtures developed up to now is given first, and then detailed description of the proposed design is presented. Finally, the results of cyclic tests carried out using new fixture are studied

Fatigue tests and microstructural observations were carried out to perform damage analysis of Al/SiC and AlMg/SiC metal matrix composites ( MMCs ). The materials were manufactured using a KoBo method. Ratcheting was the dominant damage mechanism for Al/SiC and damage parameter on the basis of mean inelastic strain was calculated. For AlMg/SiC, in most cases, cyclic softening followed by hardening during subsequent cycles were noticed. Microstructural observations identified existence of SiC concentrations which influenced the volumetric fraction of defects after fatigue tests

metal matrix composites, fatigue damage, microstructure, KoBo method