John Wertz

An Energy-Based Axial Isothermal- Mechanical Fatigue Lifing Procedure

An energy-based fatigue lifing procedure for the determination of full-life and critical-life of in-service structures subjected to axial isothermal-mechanical fatigue (IMF) has been developed. The foundation of this procedure is the energy-based axial room-temperature fatigue model, which states: the total strain energy density accumulated during both a monotonic fracture event and a fatigue process is the same material property. The energy-based axial IMF lifing framework is composed of the following entities: (1) the development of an axial IMF testing capability; (2) the creation of a testing procedure capable of assessing the strain energy accrued during both a monotonic fracture process and a fatigue process at various elevated temperatures; and (3), the incorporation of the effect of temperature into the axial fatigue lifing model. Both an axial IMF capability and a detailed testing procedure were created. The axial IMF capability was employed in conjunction with the monotonic fracture curve testing procedure to produce fifteen fracture curves at four operating temperatures. The strain energy densities for these fracture curves were compared, leading to the assumption of constant monotonic fracture energy at operating temperatures below the creep activation temperature.

An Energy-Based Experimental-Analytical Torsional Fatigue Life-Prediction Method

An energy-based fatigue life prediction framework for calculation of torsional fatigue life and remaining life has been developed. The framework for this fatigue prediction method is developed in accordance with our previously developed energy-based axial and bending fatigue life prediction approaches, which state: the total strain energy dissipated during a monotonic fracture and cyclic processes is the same material property, where each can be determined by measuring the area underneath the monotonic true stress-strain curve and the area within a hysteresis loop, respectively. The energy-based fatigue life prediction framework is composed of the following entities: (1) development of a shear fatigue testing procedure capable of assessing strain energy density per cycle in a pure shear stress state and (2) incorporation of an energy-based fatigue life calculation scheme to determine the remaining fatigue life of in-service gas turbine materials subjected to pure shear fatigue.Copyright

Validation of a Multi-Axial Fatigue Life Prediction Using Maximum Shear Experimental Results

A multi-axial prediction method is used to calculate the fatigue life of components under pure torsion loading. The general life prediction method was developed based on the understanding that the total accumulated strain energy density in a fatigue and monotonic processes is the same. Due to this understanding, the fatigue life prediction method has been used to calculate fatigue cycles of components experiencing either uniaxial, transverse shear, or multi-axial loads. This manuscript extends the capability of the multi-axial prediction method by calculating the fatigue life of components under pure torsion loads. This calculation is possible because the maximum applied shear stress from a pure torsion load can be observed as two normal principal stresses. Based on some unusual results from experimental torsion fatigue, it was assumed that a linear misalignment was present in the experimental setup. With the inclusion of this correction, a comparison between experimental torsion fatigue results and the energy-based prediction method further affirms the capability to determine fatigue life cycles in a multi-axial loading state.Copyright

Damage Parameter Assessment for Energy Based Fatigue Life Prediction Methods

An energy-based method used to predict fatigue life and critical life of various materials has been previously developed, correlating strain energy dissipated during monotonic fracture to total cyclic strain energy dissipation in fatigue fracture. This method is based on the assumption that the monotonic strain energy and total hysteretic strain energy to fracture is equivalent. The fracture processes of monotonic and cyclic failure modes can be of stark contrast, with ductile and brittle fracture dominating each respectively. This study proposes that a more appropriate damage parameter for predicting fatigue life may be to use low cycle fatigue (LCF) strain energy rather than monotonic energy. Thus, the new damage parameter would capture similar fracture processes and cyclic behavior. Round tensile specimens machined from commercially supplied Al 6061-T6511 were tested to acquire LCF failure data in fully reversed loading at various alternating stresses. Results are compared to both monotonic and cyclic strain energy dissipation to determine if LCF strain energy dissipation is a more suitable damage parameter for fatigue life prediction.© 2012 ASME

The Effect of Compressive Damage on Tensile Loading Failure of Titanium 6Al-4V

In order to explore the belief that total strain energy accumulation during monotonic tensile fracture is a universal damage parameter, the effect of compressive preloads on specimens failed via tensile loading is analyzed. The motivation behind this analysis is due to the theory of an energy-based life prediction model, which states that the total strain energy required for monotonic tensile fracture is defined as the physical damage quantity for the fatigue lifing model. Two things are observed in order to determine the effects of a compressive preload on tensile monotonic fracture. First, the compressive work is viewed as accumulated damage, thus adding to the total work necessary for failure. Second, tensile works of fractured specimens with and without stored compressive energy are compared to see if the damage parameter is affected. The analysis is conducted through experimental data acquisition from round stock Titanium 6Al-4V dogbone specimens. The results from this study show that compressive damage has a negligible effect on monotonic tensile work to fracture, and combined half-cycle tension and compression preloads have an unnoticeable effect on the tensile work of the final pull to fracture. These results contradict the theory and research validations of the energy-based predictions; however, they provide a platform for future efforts to understand the strain energy correlation between monotonic, low cycle and high cycle failures.© 2012 ASME

The Effect of Heat Generation on Low Cycle Fatigue Life Prediction

An energy-based life prediction method is used in this study to determine the fatigue life of tension-compression loaded components in the very low cycle regime between 102 and 104 . The theoretical model for the energy-based prediction method was developed from the concept that the strain energy accumulated during both monotonic failure and an entire fatigue process are equal; In other words, the scalar quantity of strain energy accumulated during monotonic failure is a physical damage quantity that correlates to fatigue as well. The energy-based method has been successfully applied to fatigue life prediction of components failing in the fatigue regime between 104 and 107 cycles. To assess Low Cycle Fatigue (LCF) with the prediction method, a clearer understanding of energy dissipation through heat, system vibration, damping, surface defects and acoustics were necessary. The first of these topics analyzed is heat. The analysis conducted studies the effect of heat generated during cyclic loading and heat loss from slipping at the interface of the grip wedges of the servo-hydraulic load frame and the test specimen. The reason for the latter is to address the notion that slippage in the experimental setup may be the cause of the reduction in the accuracy of the energy-based prediction method for LCF, which was seen in previous research. These analyses were conducted on Titanium 6Al-4V, where LCF experimental data for stress ratios R = −1 and R = −0.813 were compared with the energy-based life prediction method. The results show negligible effect on both total and cyclic energy from heat generation at the interface of the grip wedges and heat generation in the fatigue zone of the specimen.Copyright

An Energy-Based Axial Isothermal-Mechanical Lifing Procedure

An energy-based fatigue lifing procedure for the determination of fatigue life and critical life of in-service structures subjected to axial isothermal-mechanical fatigue (IMF) has been developed. The foundation of this procedure is the energy-based axial room-temperature fatigue model, which states: the total strain energy density accumulated during both a monotonic fracture event and a fatigue process is the same material property. The energy-based axial IMF lifing framework is composed of the following entities: (1) the development of an axial IMF testing capability; (2) the creation of a testing procedure capable of assessing the strain energy accrued during both a monotonic fracture process and a fatigue process at various elevated temperatures; and (3), the incorporation of the effect of temperature into the axial fatigue lifing model. Both an axial IMF capability and a detailed testing procedure were created. The axial IMF capability was employed in conjunction with the monotonic fracture curve testing procedure to produce eight fracture curves at three operating temperatures. The strain energy densities for these fracture curves were compared, leading to the assumption of constant monotonic fracture energy at operating temperatures below the creep activation temperature.Copyright