Numerical estimation of the bearing capacity of resistance spot welds in martensitic boron steels using a J-integral fracture criterion

Predicting the bearing capacity of resistance spot welds (RSW) during vehicle crash tests has become a crucial task for the automotive industry, since the recent introduction of advanced high strength steels (AHSS) such as martensitic boron steels (e.g. 22MnB5). The spot weld joints of these steels exhibit relatively low bearing strengths, compared to those of more ductile high strength steels. Currently, the bearing capacity of spot weld joints is characterized through extensive experimental campaigns. In this article, a model for quantification of the bearing capacity of RSW using a finite-element J-integral fracture criterion is presented. The model takes into account geometric and mechanical features of the spot weld, namely the weld diameter and the mechanical properties distribution resulting from the welding process. An experimental loading test campaign is carried out for calibration and validation purposes, considering multiple sheet thickness combinations, loading angles and weld sizes. Experimental observations of the failed spot welds and preliminary simulations show that failure is caused mostly by stress concentration around the sharp weld notch. Consequently, the J-integral obtained from detailed finite element simulations is used to asses the stress/strain concentration along the first crack advance direction predicted by the acoustic tensor. The computed J-integral values are compared to the material toughness to obtain the joint’s maximum force. The resulting simulated and experimental bearing capacities show a good agreement for all tested configurations

Numerical estimation of the bearing capacity of resistance spot welds in martensitic boron steels using a J-integral fracture criterion

Predicting the bearing capacity of resistance spot welds (RSW) during vehicle crash tests has become a crucial task for the automotive industry, since the recent introduction of advanced high strength steels (AHSS) such as martensitic boron steels (e.g. 22MnB5). The spot weld joints of these steels exhibit relatively low bearing strengths, compared to those of more ductile high strength steels. Currently, the bearing capacity of spot weld joints is characterized through extensive experimental campaigns. In this article, a model for quantification of the bearing capacity of RSW using a finite-element J-integral fracture criterion is presented. The model takes into account geometric and mechanical features of the spot weld, namely the weld diameter and the mechanical properties distribution resulting from the welding process. An experimental loading test campaign is carried out for calibration and validation purposes, considering multiple sheet thickness combinations, loading angles and weld sizes. Experimental observations of the failed spot welds and preliminary simulations show that failure is caused mostly by stress concentration around the sharp weld notch. Consequently, the J-integral obtained from detailed finite element simulations is used to asses the stress/strain concentration along the first crack advance direction predicted by the acoustic tensor. The computed J-integral values are compared to the material toughness to obtain the joint’s maximum force. The resulting simulated and experimental bearing capacities show a good agreement for all tested configurations.Peer ReviewedPostprint (author's final draft

Mechanochemical Reactions and Strengthening in Epoxy-Cast Aluminum Iron-Oxide Mixtures

This investigation is focused on the understanding of mechanical and chemical reaction behaviors of stoichiometric mixtures of nano- and micro-scale aluminum and hematite (Fe2O3) powders dispersed in epoxy. Epoxy-cast Al+Fe2O3 thermite composites are an example of a structural energetic material that can simultaneously release energy while providing structural strength. The structural and energetic response of this material system is investigated by characterizing the mechanical behavior under high-strain rate and shock loading conditions. The mechanical response and reaction behavior are closely interlinked through deformation characteristics. It is, therefore, desirable to understand the deformation behavior up to and beyond failure and establish the necessary stress and strain states required for initiating chemical reactions. The composite s behavior has been altered by changing two main processing parameters; the reactants particle size and the relative volume fraction of the epoxy matrix. This study also establishes processing techniques necessary for incorporating nanometric-scale reactants into energetic material systems. The mechanochemical behavior of epoxy-cast Al+Fe2O3 composites and the influence of epoxy volume fraction have been evaluated for a variety of loading conditions over a broad range of strain rates, which include low-strain rate or quasistatic loading experiments (10-4 to 10-2 1/s), medium-strain rate Charpy and Taylor impacts (103 to 104 1/s), and high-strain rate parallel-plate impacts (105 to 106 1/s). In general, structural strength and toughness have been observed to improve as the volume fraction of epoxy decreases, regardless of the loading strain rate regime explored. Hugoniot experiments show damage occurring at approximately the same critical impact stress for compositions prepared with significantly different volume fractions of the epoxy binder phase. Additionally, Taylor impact experiments have indicated evidence for strain-induced chemical reactions, which subject the composite to large shear accompanied by temperature increase and associated softening, preceding these reactions. Overall, the work aims to establish an understanding of the microstructural influence on mechanical behavior and chemical reactivity exhibited by epoxy-cast Al+Fe2O3 materials when exposed to high stress and high-strain loading conditions. The understanding of fundamental aspects and the results of impact experiment measurements provide information needed for the design of structural energetic materials.Ph.D.Committee Chair: Dr. Naresh N. Thadhani; Committee Member: Dr. David L. McDowell; Committee Member: Dr. Kenneth A. Gall; Committee Member: Dr. Min Zhou; Committee Member: Dr. Ronald W. Armstrong; Committee Member: Dr. Yasuyuki Hori

Experimental optimization of simulated ring rolling operation for heavy rail industry

“Industrially cast AISI 1070 steel wheel pre-forms from Amsted Rail Co. were experimentally hot rolled to simulate the conditions for industrial wheel rolling. Ring rolling of near net shape castings can improve location specific properties by decreasing segregation, closing porosity, and reducing grain size without the use of multiple forging operations in a traditional forging line. As-cast wheel sections were subjected to thermomechanical processing routes using a 2-high rolling mill in a temperature range of 830°C to 1200°C. The goal being to simulate the ring rolling process and optimize benefits of mechanical properties of the as-rolled steel. Charpy V- and U-notch impact tests were conducted at -20ºC and 20ºC, respectively, as a function of thermomechanical processing and notch orientation. Mitigation of cast defects such as inclusions and shrinkage porosity by hot rolling were quantified utilizing scanning electron microscopy and micro-computed X-Ray tomography. Microshrinkage porosity was shown to be virtually eliminated at a 66% reduction. A rolling temperature of 830°C resulted in a 114% increase in KCU at 20°C and 67% increase at -20°C in KCV for L-S impact properties through refinement of prior austenite grain size. Anisotropy related to MnS stringers in the rolling direction were the primary cause for reduction in impact toughness in the T-L orientation although grain texture also likely plays a role. Hot tensile tests performed between 830°C to 1200°C in strain rates of 0.1 to 10 s-1 were utilized to develop a Johnson-Cook Strength model. The experimental parameters determined from the Johnson-Cook model were used as inputs to develop a Finite Element Analysis model of the modified wheel rolling process utilizing FORGE NxT software”--Abstract, page iv

Microstructure-sensitive fatigue modeling of heat treated and shot peened martensitic gear steels

High strength secondary hardening lath martensitic steel is a strong candidate for high performance and reliable transmission systems in aircraft and automotives. The fatigue resistance of this material depends both on intrinsic microstructure attributes, such as fine scale (M2C) precipitates, and extrinsic attributes such as nonmetallic primary inclusions. Additionally, the aforementioned attributes are affected by processing history. The objective of this research is to develop a computational framework to quantify the influence of both extrinsic (primary inclusions and residual stresses) and intrinsic (martensite laths and carbides) microstructure attributes on fatigue crack formation and the early stage of microstructurally small crack (MSC) growth that dominate high cycle fatigue (HCF) lifetime. To model the fatigue response at various microstructure scales, a hierarchical approach is adopted. A simplified scheme is developed to simulate processing effects such as shot peening that is suitable to introduce representative residual stresses prior to conducting fatigue calculations. Novel strategies are developed to couple process route (residual stresses) and microstructure scale response for comprehensive analysis of fatigue potency at critical life-limiting primary inclusions in gear steels. Relevant microstructure-scale response descriptors that permit relative assessment of fatigue resistance are identified. Fatigue crack formation and early growth is highly heterogeneous at the grain scale. Hence, a scheme for physically-based constitutive models that is suitable to investigate crack formation and early growth in martensitic steel is introduced and implemented. An extreme value statistical/probabilistic framework to assess the influence of variability of various microstructure attributes such as size and spatial distribution of primary inclusions on minimum fatigue crack formation life is devised. Understanding is sought regarding the relative role of microstructure attributes in the HCF process, thereby providing a basis to modify process route and/or composition to enhance fatigue resistance. Parametric studies are conducted to assess the effect of hot isostatic pressing and introduction of compliant coatings at debonded inclusion-matrix interface on enhancement of fatigue resistance. A comprehensive set of 3D computational tools and algorithms for hierarchical microstructure-sensitive fatigue analysis of martensitic gear steels is developed as an outcome of this research; such tools and methodologies will lend quantitative and qualitative support to designing improved, fatigue-resistant materials and accelerating insertion of new or improved materials into service.Ph.D.Committee Chair: David L. McDowell; Committee Member: G. B. Olson; Committee Member: K. A. Gall; Committee Member: Min Zhou; Committee Member: R. W. Ne

Tension-induced tunable corrugation in two-phase soft composites and its properties as a band gap structure

This thesis numerically investigates the elastic deformation response of a two-phase soft composite under externally applied concentric tension and its properties as a band gap structure. By carefully designing the inclusion pattern, it is possible to induce corrugations normal to the direction of stretch. By stacking 1D composite fibers to form 2D membranes, these corrugations collectively lead to the formation of membrane channels with shapes and sizes tunable by the level of stretch and enable the interfaces to progressively soften and evolve into non-planar geometries characterized by the nucleation and stable growth of interfacial channels of irregular shapes. It is also possible to modulate the band gap profile of the composite structure as a result of interfacial deformations and the corresponding microstructural evolution. Furthermore, by using specific inclusion patterns in laminated plates, it is possible to create pop-ups and troughs enabling the development of complex 3D geometries from planar construction. The corrugation amplitude increases with the stiffness of inclusion and its eccentricity from the tension axis. The techniques discussed in this thesis provide greater flexibility and controllability in pattern design and have potential applications in providing a novel framework for harnessing controlled damage in the development of targeted acoustic band gaps and optimizing damping properties of composites

The influence of oxide deposits on the remaining life and integrity of pressure vessels equipment

In this paper is presented the principle of application of fracture mechanics parameters in determining the integrity of rotary equipment. The behavior of rotary equipment depends on presence of cracks and basically determines the integrity and life of such equipment. The locations of stress concentration (i.e. radius changes) represent a particular problem in rotary equipment, and they are the most suitable places for the occurrence of microcracks i.e. cracks due to fatigue load. This problem is most common in the shaft of relatively large dimensions, for example, turbine shafts in hydropower plants made of high-strength carbon steel with relatively low fracture toughness, and relatively low resistance to crack formation and growth. Having in mind that rotary equipment represents the great risk in the exploitation, whose occasional failures often had severe consequences, it is necessary detail study of their integrity. For this purpose, it is necessary application of parameters of linear-elastic fracture mechanics, such as stress intensity factor, which range defines the rate of crack growth (Parisian law), and its critical value (fracture toughness) determines the critical crack length. The procedures for determining the critical crack length will be described using the fracture mechanics parameters

Numerical analysis of fatigue crack growth in welded joints with multiple defects

In the case of welded steel structures (such as pressure equipment), welded joints are often critical location for stress concentrations, due to different mechanical properties and chemical composition compared to the parent material, and due to changes in geometry. In addition, the presence of imperfections (defects) in welded joints can contribute to the increase in local stress, resulting in crack initiation. Recently, standards that are related to acceptable dimensions of various types of defects in welded joints started taking fatigue loading into account as well. For the purpose of this research, a 3D numerical model was made, of a welded joint with different types of defects (linear misalignment and a crack in the weld metal), based on the previous work, which involved static loading of the same specimen. In this case, fatigue was taken into account, and the simulation was performed using ABAQUS software, as well as Morfeo, an add-on used for determining the fatigue behaviour of structures via XFEM (extended finite element method). The welded joint was made using steel P460NL1 as the parent material, and EPP2NiMo2 wire was used for the weld metal. An additional model was made, whose defects included a crack and an overhang. Fatigue crack growth analysis was performed for this model as well, and the results for stress intensity factors and stress/strain distribution were compared in order to obtain information about how different defects can affect the integrity of a welded joint

Using the fracture mechanics parameters in assessment of integrity of rotary equipment

In this paper is presented the principle of application of fracture mechanics parameters in determining the integrity of rotary equipment. The behavior of rotary equipment depends on presence of cracks and basically determines the integrity and life of such equipment. The locations of stress concentration (i.e. radius changes) represent a particular problem in rotary equipment, and they are the most suitable places for the occurrence of microcracks i.e. cracks due to fatigue load. This problem is most common in the shaft of relatively large dimensions, for example, turbine shafts in hydropower plants made of high-strength carbon steel with relatively low fracture toughness, and relatively low resistance to crack formation and growth. Having in mind that rotary equipment represents the great risk in the exploitation, whose occasional failures often had severe consequences, it is necessary detail study of their integrity. For this purpose, it is necessary application of parameters of linear-elastic fracture mechanics, such as stress intensity factor, which range defines the rate of crack growth (Parisian law), and its critical value (fracture toughness) determines the critical crack length. The procedures for determining the critical crack length will be described using the fracture mechanics parameters

Space-Time Multiscale-Multiphysics Homogenization Methods for Heterogeneous Materials

We present a unified, homogenization framework for computational analysis of heterogeneous materials consisting of multiple length scales, multiple time scales and coupled-multiple physics. The research efforts also addresses the technological issues associated with modeling the morphological details of microstructures with randomly distributed inclusions. The Random Sequential Adsorption (RSA) algorithm is improved to accurately and effectively model the morphological details of materials with randomly distributed inclusions. The proposed algorithm is more robust; computational efficient and versatile in comparison to the existing methods. A temporal homogenization scheme is developed and integrated with the previously developed spatial homogenization theory for fatigue life analysis of heterogeneous materials. The unified space-time multiscale homogenization model is validated for fatigue life prediction of elevated temperature Ceramic Matrix Composites (CMCs). In the final phase of the research a mathematical model for coupled moisture diffusion-mechanical deformation is developed. This model is integrated with the spatial homogenization framework to analyze problems consisting of multiple length scales and coupled-multiple physics. The unified multiscale-multiphysics model is validated for evaluating the degradation of physical and mechanical properties of short glass fiber and carbon fiber filled thermoplastic material systems