Soo Yeol Lee

Neutron and X-ray diffraction studies and cohesive interface model of the fatigue crack deformation behavior

The crack-tip deformation behavior during a single overload, fatigue test of ferritic stainless steel, and Ni-based HAYNES 230 superalloy is studied at different structural levels using (1) neutron-diffraction, from which both the elastic-lattice strain and volume-averaged total dislocation densities are obtained, (2) polychromatic X-ray microdiffraction to probe the geometrically necessary dislocations and boundaries distribution, and (3) an irreversible and hysteretic cohesive interface model which has been implemented into a finite element framework to simulate the stress/strain evolution near the fatigue crack tip. Neutron strain measurements and finite element simulations are in qualitative agreement on the macroscopic length scale. Large plastic deformation induced by the overload and the resulting compressive residual strains are observed in front of the crack tip after the overload, and are the principal reason for the fatigue-crack-growth retardation. Strong strain gradients surrounding the crack propagation result in the formation of a high density of geometrically necessary dislocations near the fractured surface and cause local lattice rotations on the submicron level.

Three-Orthogonal-Direction Stress Mapping around a Fatigue-Crack Tip Using Neutron Diffraction

Quantitative determination of the stress fields around the crack tip is a challenging and important subject to understand the fatigue crack-growth mechanism. In the current study, we measured the distribution of residual stresses and the evolution of the stress fields around a fatigue crack tip subjected to the constant-amplitude cyclic loading in a 304L stainless steel compact-tension (CT) specimen. The three orthogonal stress components (i.e., crack growth, crack opening, and through thickness) of the CT specimen were determined as a function of distance from the crack tip with 1-mm spatial resolution along the crack-propagation direction. In-situ neutron-diffraction results show that the enlarged tensile stresses were developed during loading along the through-thickness direction at a localized volume close to the crack tip, resulting in the lattice expansion in all three orthogonal directions during Pmax. The current study suggests that the atypical plane strainlike behavior observed at the midthickness position might be the reason for the mechanism of the faster crack-growth rate inside the interior than that near the surface.

Plastic Deformation of Magnesium Alloy Subjected to Compression-First Cyclic Loading

In-situ neutron diffraction has been employed to study the deformation mechanisms in a precipitation-hardened and extruded Mg-8.5wt.% Al alloy subjected to compression followed by reverse tension. The starting texture is such that the basal poles of most grains are oriented normal to the extrusion axis and a small portion of grains are oriented with the basal pole parallel to the extrusion axis. Diffraction peak intensities for several grain orientations monitored in-situ during deformation show that deformation twinning plays an important role in the elastic-plastic transition and subsequent plastic deformation behavior. Significant non-linear behavior is observed during unloading after compression and appears to be due to detwinning. This effect is much stronger after compressive loading than after tensile loading.

Micromechanical Behavior of Solid-Solution-Strengthened Mg-1wt.%Al Alloy Investigated by In Situ Neutron Diffraction

In-situ neutron diffraction experiments were employed to investigate the micromechanical behavior of solid-solution-strengthened Mg-1wt.%Al alloy. Two starting textures were used: 1) as-extruded then solutionized texture, T1, in which the basal poles of most grains are tilted around 70~85° from the extrusion axis, and 2) a reoriented texture, T2, in which the basal poles of most grains are tilted around 10~20° from the extrusion axis. Lattice strains and diffraction peak intensity variations were measured in situ during loading-unloading cycles in uniaxial tension. Twinning activities and stress states for various grain orientations were revealed. The results show that the soft grain orientations, favorably oriented for either extension twinning or basal slip, exhibit stress relaxation, resulting in compressive residual strain after unloading. On the other hand, the hard grain orientations, unfavorably oriented for both extension twinning and basal slip, carry more applied load, leading to much higher lattice strains during loading followed by tensile residual strains upon unloading.

Correlation of eddy current responses between fatigue cracks and electrical-discharge-machining notches

The eddy current responses of Electrical Discharge Machining (EDM) notches and fatigue cracks are directly compared to verify the reliability of eddy current inspection. The fatigue crack growth tests using a constant load range control mode were conducted to obtain a variety of edge crack sizes, ranging from 0.9 to 6.6 mm for Al alloy and from 0.1 to 3 mm for Ti alloy. EDM notch specimens of Al and Ti alloys were accordingly prepared in lengths similar to that of the fatigued specimen. The crack length was determined by optical microscope and scanning electron microscope. The eddy current responses between the EDM and fatigued specimens with varying notch/crack length were examined using probe sensors at (100-500) kHz and (1-2) MHz for Al and Ti alloys, respectively. The results show a significant difference in the eddy current signal between the two specimens, based on the correlation between the eddy current response and notch/crack length. This suggests that eddy current inspection using the EDM reference specimen is inaccurate in determining the precise crack size, unless the eddy current response data base is obtained from a fatigue-cracked specimen.

Investigation of Microstructure and Mechanical Properties of KR60 Rail

The use of continuous welded rail is increasing because of its many advantages, including vibration reduction, enhanced driving stability, and maintenance cost savings. In this work, two different types of continuous welded rails were examined to determine the influence of repeated wheel-rail contact on the crystal structure, microstructure and mechanical properties of the rails. The crystal structure was determined by x-ray diffraction, and the microstructure was examined using optical microscopy and scanning electron microscopy. Tensile and microhardness tests were conducted to examine the mechanical behaviors of prepared specimens taken from different positions in the cross section of both newly manufactured rail and worn rail. Analysis revealed that both the new and worn rail had a mixed microstructure consisting of ferrite and pearlite. The specimens from the top position of each rail exhibited decreased lamella spacing of the pearlite and increased yield strength, ultimate tensile strength and hardness, as compared with those from other positions of the rail. It is thought that the enhanced mechanical property on the top position of the worn rail might be explained by a mixed effect resulting from a directional microstructure, the decreased lamella spacing of pearlite, and work hardening by the repeated wheel-rail contact stress.

Effect of Strain Path on Lattice Strain Evolution during Monotonic and Cyclic Tension of Magnesium Alloy

In-situ neutron diffraction has been employed to examine the effect of strain path on lattice strain evolution during monotonic and cyclic tension in an extruded Mg-8.5wt.%Al alloy. In the cyclic tension test, the maximum applied stress increased with cycle number. Lattice strain data were acquired for three grain orientations, characterized by the plane normal to the stress axis. The lattice strain in the hard {10.0} orientation, which is unfavorably oriented for both basal slip and {10.2} extension twinning, evolved linearly throughout both tests during loading and unloading. The {00.2} orientation exhibited significant relaxation associated with {10.2} extension twinning. Coupled with a linear lattice strain unloading behavior, this relaxation led to increasingly compressive residual strains in the {00.2} orientation with increasing cycle number. The {10.1} orientation is favorably oriented for basal slip, and thus showed a soft grain behavior. Microyielding occurred in the monotonic tension test and in all cycles of the cyclic test at an applied stress of ~50 MPa, indicating that strain hardening in this orientation was not completely stable from one cycle to the next. The lattice strain unloading behavior was linear in the {10.1} orientation, leading to a compressive residual strain after every cycle, which, however, did not increase systematically from one cycle to the next as in the {00.2} orientation.

Fatigue Crack-Tip Stress Mapping Using Neutron Diffraction

Fatigue crack growth experiments were carried out on a 304 L stainless steel compact-tension(CT) specimen under load control mode. Neutron diffraction was employed to quantitatively measure the residual strains/stresses and the evolution of stress fields in the vicinity of a propagating fatigue-crack tip. Three principal stress components (i.e. crack growth, crack opening, and through-thickness direction stresses) were examined in-situ under loading as a function of distance from the crack tip along the crack-propagation path. The stress/strain fields, measured both at the mid-thickness and near the surface of the CT specimen, were compared. The results show that much higher compressive residual stress fields developed in front of the crack tip near the surface than developed at the mid-thickness area. The change of the stresses ahead of the crack tip under loading is more significant at the mid-thickness area than it is near the surface.

Thermal-Effect Study on a Carbon-Carbon Composite Using Synchrotron X-Ray Measurements & Molecular Dynamics Simulation

Carbon-carbon composites are deemed as candidate materials for application in very high temperature reactors. In a very high temperature reactor, carbon-carbon composite materials would experience severe environmental impacts from high temperatures. As a result, we applied non-destructive ex-situ diffraction experiments to investigate the microstructure changes of the carbon-carbon composite materials experiencing different temperatures. In this study, the samples were prepared in a format of a three-dimensional pitch-based carbon-carbon composite. The samples were heated to 500 (°C), 700 (°C), and 900 (°C) for 2 minutes, respectively. In order to understand the temperature effect on carbon-carbon composite, we facilitated the high penetration of the synchrotron X-ray diffraction at National Synchrotron Radiation Research Center to examine the evolution of microstructures subjected to heat treatment. The results show that the lattice parameters of a-axis and c-axis evolve upon heating. The molecular dynamics simulation results suggest that the early-stage rearrangement is originated from the release of the defects.

Residual Strain Distribution around a Fatigue-Crack Tip Determined by Neutron Diffraction

An analysis of residual stress, one of the contributory factors to the crack tip driving force, is extremely important to probe the fatigue crack growth mechanism and to further develop the life prediction methodology. Since fatigue crack growth is governed by crack-tip plasticity and crack closure in the wake of the crack tip, the investigation of residual stain/stress field in both behind and in front of the crack tip is crucial. In the current work, a 304L stainless steel compact-tension specimen is pre-cracked under constant-amplitude cyclic loading. Neutron diffraction is employed to directly measure the three orthogonal residual strain fields with 1-mm spatial resolution as a function of distance from the crack tip. The mapping results show that the three orthogonal residual-strain distributions around the crack tip depend on the stress multiaxiality, not following a single Poisson relationship to each axis.