Grzegorz Lesiuk

Algorithms for the estimation of fatigue crack growth using energy method

A new method of producing kinetic fatigue failure diagrams (KFFD) has been developed by the authors on the basis of experimental results obtained from the study of the hysteresis loop area. For experimental verification of KFFD the results of fatigue crack propagation studies for 41Cr4 (40H) and S355JR (18G2A) steels have been used. Two kinds of kinetic fatigue failure diagrams have been produced. In the first diagram (the classic one), the stress intensity factor K that characterizes the intensity of deformation in the precrack zone ahead of a crack tip was used for building the diagram. In the second diagram (the new one), energetic parameter Δ H that corresponds to the searched energy dissipation of deformation was applied. In contrast to the d a /d N – K max diagrams, in the d a /d N – Δ H diagrams obtained for a given range of the crack growth rate no difference in failure kinetics has been found. It means that the energetic parameter Δ H describes fatigue crack growth rate regardless of stress ratio R in opposition to the force

Fatigue crack propagation prediction of a pressure vessel mild steel based on a strain energy density model

Fatigue crack growth (FCG) rates have traditionally been formulated from fracture mechanics, whereas fatigue crack initiation has been empirically described using stress-life or strain-life methods. More recently, there has been efforts towards the use of the local stress-strain and similitude concepts to formulate fatigue crack growth rates. A new model has been developed which derives stress-life, strain-life and fatigue crack growth rates from strain energy density concepts. This new model has the advantage to predict an intrinsic stress ratio effect of the form ?ar=(?amp)?·(?max )(1-?), which is dependent on the cyclic stress-strain behaviour of the material. This new fatigue crack propagation model was proposed by Huffman based on Walkerlike strain-life relation. This model is applied to FCG data available for the P355NL1 pressure vessel steel. A comparison of the experimental results and the Huffman crack propagation model is made.

Description of fatigue crack growth in steel structural components using energy approach - Influence of the microstructure on the FCGR

In this paper, the theoretical and experimental results of fatigue crack growth in AISI 5140 steel have been presented. According to the previous theoretical background - the energy parameter ΔH is introduced as a crack driving force in construction of fatigue crack growth rate (FCGR) diagrams. The physical explanation of this model is also presented. In experimental parts of this work, the kinetics fatigue fracture diagrams (KFFD) for AISI 5140 steel were constructed. The main goal of experimental works was to investigate the influence of microstructure on kinetics of fatigue crack growth. The AISI 5140 steel were tested in three different heat treatment conditions. As it has been confirmed, the energy parameter ΔH describes the kinetics of fatigue crack growth much more synonymously than the classical stress intensity factor - ΔK.

Mechanical characterization of ancient Portuguese riveted bridges steels

In repairing and retrofitting processes of ancient riveted steel bridges is crucial to assess the structural state of old metals to guaranty structural safety. Metals under long-time operations (mild, rimmed low carbon steels <0.1% C, puddle irons) and cyclic loading present a tendency for degradation processes. The case-studies of this work are five metallic bridges existing in Portugal (Luiz I, Eiffel, Fao, Pinhao and Trezoi). This work presents the study of some characteristics of materials extracted from the five case-studies, such as: monotonic tensile strength, chemical composition, microstructures, hardness, notch toughness and fatigue crack propagation. In terms of monotonic tensile tests, the materials from Luiz I, Eiffel and Fao bridges are similar to puddle steel and the materials from Pinhao and Trezoi bridges are similar to mild steel. In terms of toughness only the material from the Pinhao bridge exhibits acceptable toughness properties, considering current design requirements. The materials from the other bridges exhibit relatively low toughness properties. The fatigue crack propagation data from the old Portuguese riveted steel bridges were correlated using the Paris’s law and the possibility for a design crack growth rate was discussed.

Numerical estimation of stress intenisty factors and crack propagation in lug connector with existing flaw

In this paper, series of FEM analyses were performed to define stress intensity factors in 42CrMo4 steel lug joint and predict cycling crack growth. An eXtended Finite Element Method were used in computations to investigate influence of different types of boundary conditions. Crack geometry was assumed as through - thickness. The Results of stress intensity factors for stationary cracks were compared with Newman and Schijve analytical solutions. Crack paths were obtained for 2D by implementing Paris Law coupled with crack propagation criterion and direct cycling algorithm for three different hardness of steel (28,42,54 HRC). All the studies were computed an pre–processed in ABAQUS environment.

Kinetics of fatigue crack growth and crack paths in the old puddled steel after 100-years operating time

The goal of the authors’ investigations was determination of the fatigue crack growth in fragments of steel structures (of the puddled steel) and its cyclic behavior. Tested steel elements coming from the turn of the 19th and 20th were gained from still operating ancient steel construction (a main hall of Railway Station, bridges etc.). This work is a part of investigations devoted to the phenomenon of microstructural degradation and its potential influence on their strength properties. The analysis of the obtained results indicated that those long operating steels subject to microstructure degradation processes consisting mainly in precipitation of carbides and nitrides inside ferrite grains, precipitation of carbides at ferrite grain boundaries and degeneration of pearlite areas [1, 2]. It is worth noticing that resistance of the puddled steel to fatigue crack propagation in the normalized state was higher. The authors proposed the new kinetic equation of fatigue crack growth rate in such a steel. Thus the relationship between the kinetics of degradation processes and the fatigue crack growth rate also have been shown. It is also confirmed by the materials research of the viaduct from 1885, which has not shown any significant changes in microstructure. The non-classical kinetic fatigue fracture diagrams (KFFD) based on deformation (??) or energy (?W) approach was also considered. In conjunction with the results of low- and high-cycle fatigue and gradual loss of ductility as a consequence (due to the microstructural degradation processes) - it seems to be a promising construction of the new kinetics fatigue fracture diagrams with the energy approach.

Fatigue resistance curves for single and double shear riveted joints from old portuguese metallic bridges

Abstract The maintenance and safety of ancient bridges is a major concern of governmental authorities. In particular, the safety of old riveted bridges fabricated and placed into service at the end of the 19th century deserves particular attention. These structures are susceptible to exhibit high fatigue damage levels due to their long operational period with increasing traffic intensity associated to an original design not covering the fatigue phenomenon. This paper reviews recent fatigue behaviour investigations on single and double shear riveted joints performed by Universities of Porto (Portugal), Tras-os-Montes e Alto Douro (Portugal), and Wroclaw (Poland), in particular concerning the fatigue characterization of riveted joints extracted from representative Portuguese riveted bridges, namely the Eiffel, Luiz I, Fao, Pinhao and Trezoi bridges. In order to overcome the influence of scatter and establish a reliable assessment for the obtained experimental data, two statistical approaches were used: implement linearized boundaries following the recommendation in ASTM E739 standard and defining probabilistic S N fields using the Castillo & Fernandez-Canteli model. This statistical analysis allows to propose design S N curves for single and double riveted joints and evaluate the applicability (safety) of using the design curves suggested in Eurocode 3 as well as design curves proposed by Taras and Greiner.

Probabilistic Fatigue Crack Initiation and Propagation Fields Using the Strain Energy Density

The fatigue crack growth (FCG) has been widely studied by the scientific community. There are several proposed FCG models, the best known being the Paris relation. The fatigue crack initiation and propagation have been studied separately, however, researchers have made an effort to study the relationship between these two fatigue phenomena. In this sense, several fatigue crack growth models based on local approaches have been proposed, the UniGrow model being well-known. The fatigue crack growth process is assumed a succession of crack re-initiations considering a certain elementary material size. Recently, Huffman developed a strain energy density based on Walker-like stress life and fatigue crack growth behavior. In this paper, the Huffman model based on local strain energy density is used to predict the fatigue crack initiation and propagation for the P355NL1 pressure vessel steel. This model is combined with the generalized probabilistic fatigue model proposed by Correia aiming the generation of probabilistic fatigue crack initiation and propagation fields. In this study, the local stress and strains at the crack tip were obtained combining linear-elastic and elastoplastic analyses. The probabilistic fatigue crack growth rates fields for several stress R-ratios are estimated considering strain, SWT, and equivalent stress amplitude damage parameters. A comparison between the experimental FCG data and the generated probabilistic FCG fields is made with very satisfactory correlations being found.

Energy response of S355 and 41Cr4 steel during fatigue crack growth process

In this research, a novel approach of the fatigue crack growth rate description has been proposed. Based on theoretical and experimental approach, the mean stress effect expressed by R-ratio is present in classical da/dN–ΔK diagram. According to energy approach – based on the irrevocably dissipated energy accumulated in material (hysteresis loop) during fatigue process – the mean stress effect can be minimalized. Experimental validation of the proposed model was performed using results of fatigue crack propagation data for S355 and 41Cr4 steels in terms of strain energy density parameter ΔS or cyclic J-integral range –ΔJ. In contrast to the force approach based on Kmax (or ΔK), the energy parameters ΔS or ΔJ represent unambiguously the fatigue crack propagation rate, without influence of mean stress effect –R-ratio. However, in near threshold range of kinetic fatigue fracture diagram, the energy parameter displays a slight dispersion of the experimental data. According to the crack closure theory and its U-Elber parameter, the dispersion of experimental data is decreased. Therefore, the crack closure effects have a high significance in energy model – similar to the ‘force approach’ based on ΔK concept.

Fatigue crack growth rate in CFRP reinforced constructional old steel

Purpose The purpose of this paper is twofold: first, to observe an influence of different Composite Fibre-Reinforced Polymer (CFRP) patches, whose application to metals is very easy, in suppling and significantly elongating the service time; and second, the numerical calculation of the reduced stress intensity factor (SIF) range for strengthened cracked steel specimens. Design/methodology/approach One of the successful strengthening methods is the CFRP patching along the fatigue crack paths. The presented approach has been studied and discussed in this paper on the background of the numerical and experimental data. As it was expected, the proposed strengthening method is efficient and promising in case of the “immediate” repairs of critical members with cracks. The manufacturing process of specimens and test methodology as well as numerical approach to calculate SIFs for various reinforcements of steel specimens are presented. For this purpose, the Extended Finite Element Method was involved and described. Findings The main mechanism of fatigue crack growth retardation is associated with local ΔK reduction due to CFRP patches; any type of reinforcement results in an increase in af and a significant decrease in SIF values. The beach-marking method is described as a good, reliable and comprehensive method to capture the crack propagation in structures consisting of various materials and could be applied successfully for mixed mode testing. Originality/value A detailed experimental-numerical approach for fatigue crack growth in long-term operated structures made of steel is presented. The strengthening methodology is presented with consideration of the various CFRP patches configurations.