Fuzzy logic approach in metals fatigue

AbstractThe fatigue behavior of metal structures is extremely complex. Many types of uncertainty exist in metal fatigue studies, including member geometry; shape and size of fatigue cracks; type, shape, and size of defects and discontinuities in the structural detail; loading and environmental conditions; and thermal and corrosive effects. This article reviews a number of factors affecting the fatigue behavior of metal members. An example problem is presented to illustrate the use of fuzzy sets to evaluate the acceptability of a welded structural detail

Challenges towards Structural Integrity and Performance Improvement of Welded Structures

Welding is a fabrication process that joint materials, is extensively utilized in almost every field of metal constructions. Heterogeneity in mechanical properties, metallurgical and geometrical defects, post-weld residual stresses and distortion due to non-linear welding processes are prime concerns for performance reduction and failures of welded structures. Consequently, structural integrity analysis and performance improvement of weld joints are important issues that must be considered for structural safety and durability under loading. In this study, an extensive experimental program and analysis were undertaken on the challenges towards structural integrity analysis and performance improvement of different welded joints. Two widely used welding techniques including solid-state “friction- stir- welding (FSW)” and fusion arc “gas tungsten arc welding (GTAW)” were employed on two widely utilized materials, namely aluminum alloys and structural steels. Various destructive and non-destructive techniques were utilized for structural integrity analysis of the welded joints. Furthermore, various “post-weld treatment (PWT)” techniques were employed to improve mechanical performances of weld joints. The work herein is divided into six different sections including: (i) Establishment of an empirical correlation for FSW of aluminum alloys. The developed empirical correlation relates the three critical FSW process parameters and was found to successfully distinguish defective and defect-free weld schedules; (ii) Development of an optimized “adaptive neuro-fuzzy inference system (ANFIS)” model utilizing welding process parameters to predict ultimate tensile strength (UTS) of FSW joints; (iii) Determination of an optimum post-weld heat treatment (PWHT) condition for FS-welded aluminum alloys; (iv) Exploration on the influence of non-destructively evaluated weld-defects and obtain an optimum PWHT condition for GTA-welded aluminum alloys; (v) Investigation on the influence of PWHT and electrolytic-plasma-processing (EPP) on the performance of welded structural steel joints; and finally, (vi) Biaxial fatigue behavior evaluation of welded structural steel joints. The experimental research could be utilized to obtain defect free weld joints, establish weld acceptance/rejection criteria, and for the better design of welded aluminum alloy and steel structures. All attempted research steps mentioned above were carried out successfully. The results obtained within this effort will increase overall understanding of the structural integrity of welded aluminum alloys and steel structures

Multi-criteria risk assessment approach for components risk ranking - The case study of an offshore wave energy converter

Experts’ judgement is employed in offshore risk assessment because reliable failure data for quantitative risk analysis are scarce. The challenges with this practice lies with knowledge-based uncertainties which renders risk expression and estimation, hence components’ risk-based prioritisation, subjective to the assessor – even for the same case study. In this paper, a new risk assessment framework is developed to improve the fidelity and consistency of prioritisation of components of complex offshore engineering systems based on expert judgement. Unlike other frameworks, such as the Failure Mode and Effect Criticality Analysis, it introduces two additional dimensions: variables and parameters, to allow more effective scoring. These additional dimensions provide the much needed and uniform information that will assist experts with the estimation of probability of occurrence, severity of consequence and safeguards, herein referred to as 3-D methodology. In so doing, it achieves a more systematic approach to risk description and estimation compared to the conventional Risk Priority Number (RPN) of FMECA. Finally, the framework is demonstrated on a real case study of a wave energy converter (WEC) and conclusions of the assessment proved well in comparison and prioritisation

A knowledge base system approach to inspection scheduling for fixed offshore platforms

In the offshore oil and gas industry in the UK, one of the most common forms of structure is the fixed steel jacket type of offshore platform. These are highly redundant structures subject to many random or uncertain factors. In particular, they are subject to uncertainties in the load distribution through the components, and to time-varying and cyclic loads leading to deterioration through fatigue. Operators are required to ensure the integrity of these structures by carrying out periodic inspections and repairing when necessary. Decisions on inspection, repair and maintenance (IRM) actions on structures involves making use of various tools and can be a complex problem. Traditionally, engineering judgement is employed to schedule inspections and deterministic analyses are used to confirm decisions. The use of structural reliability methods may lead to more rational scheduling of IRM actions. Applying structural reliability analysis to the production of rational inspection strategies, however, requires understanding the inspection procedure and making use of the appropriate information on inspection techniques. There are difficulties in collecting input data and the interpreted results need to be combined to form a rational global solution for the structure which takes into account practical constraints. The development of a knowledge base system (KBS) for reliability based inspection scheduling (RISC) provides a way of making use of complex quantitative objective analyses for scheduling. This thesis describes the development of a demonstrator RISC KBS. The general problems of knowledge representation and scheduling are discussed and schemes from Artificial Intelligence are proposed. Additionally, a system for automated inspection is described and its role in IRM of platforms is considered. A RISC System integrating suitable databases with fatigue fracture mechanics based reliability analysis within a KBS framework will enable operators to develop rational IRM scheduling strategies

Influence of geometrical imperfections and flaws at welds of steel liners on fatigue behavior of pressure tunnels and shafts in anisotropic rock

The recent development of high-strength (HSS) weldable steels has enlarged the range of design alternatives for the optimization of high-head steel-lined pressure tunnels and shafts (SLPT&S) in the hydropower industry. With the liberalization of the European energy market and increasing contribution of new renewable volatile energies in the electricity grid due to high subsidies, storage hydropower and pumped-storage plants are subject to more and more severe operation conditions resulting in more frequent transients. The use of HSS allows the design of thinner and thus more economic steel liners. However, welded HSS do not provide higher fatigue resistance than lower steel grades, and may be particularly subject to the risk of cold cracking in the weld material as dramatically illustrated by the failure of the Cleuson-Dixence pressure shaft in 2000. Fatigue behavior may become the leading limit state criterion. This research project aims at improving the comprehension of the mechanical behavior of SLPT&S and at developing a framework for probabilistic fatigue crack growth and fracture assessment of crack-like flaws in the weld material of longitudinal butt welded joints, considering all possible steel grades for high-head hydropower schemes. The influence of anisotropic rock behavior and geometrical imperfections at the longitudinal joints on the structural stresses have been studied by means of the finite element method accounting for the interaction with the backfill concrete-rock multilayer system. Parametric correction factors have been derived to estimate stress concentrations and structural stresses in steel liners with ease in practice, allowing the use of $S$-$N$ based engineering fatigue assessment approaches. Stress intensity factors (SIF) for axial cracks in the weld material of the longitudinal joints have also been obtained by means of computational linear elastic fracture mechanics (LEFM). The use of the previously developed parametric equations in the classical formulas for SIF in cracked plated structures has been validated, and new parametric equations for the weld shape correction have been proposed. A probabilistic model for fatigue crack growth assessment has been developed in the framework of LEFM in combination with the Paris-Erdogan law. The probability of failure is estimated by means of the Monte Carlo simulation procedure, in which the crack growth rate parameters and the crack shape ratio are defined as stochastic variables. A week-long normalized loading spectrum derived from prototype measurements on an alpine pumped-storage hydropower plant in Switzerland is used. This approach provides relative and quantitative results through parametric studies, giving new insights on the fatigue behavior of steel liners containing cracks in the weld material of the longitudinal joints. Finally, a fatigue assessment case study is presented, detailing the entire calculation procedures developed in this research. It aims at ensuring the transfer of knowledge toward practitioners

Ultrasonic Spot Welding of Dissimilar Metal Sheets: An Experimental, Numerical and Metallurgical Investigation

Ultrasonic metal welding (USMW) is a new and emerging concept used in the industries over the past twenty years and serving to the manufacturing sectors like aviation, medical, microelectronics, automotive and much more due to various hurdles faced by conventional fusion welding process. USMW is a clean and reliable technique in which the welding takes place with a high energy, no flux or filler metal needed, longer tool life and it takes very short time (less than one second) to weld materials in a perfect controllable environment with greater efficiency.To acquire high vibration amplitude in USMW, there is a necessity to design a welding system that consists of components like a booster and horn. The principal purpose of these parts is to amplify the input amplitude of vibration so that the energy transferred to the welding spot should be sufficient for creating a joint. In the present study, new type of booster and horn are proposed and modelled with adequate precision not only to produce high-quality welds but also to solve a lot of issues faced while designing these types of ultrasonic tools. The modal analysis module of finite element method (FEM) is used to analyze the effects of different step lengths and fillet radius on its natural frequency of 20 kHz, ensuring that these components will be in a resonating condition with other parts of the system. It is found that there were 1.11 % and 2.52 % errors in the length calculation of both parts. Similarly, 0.61 % error is obtained for both while calculating the magnification ratio. However, such low levels of errors may be considered to be insignificant. The dynamic analysis has also been performed to find out the stress distribution in both parts under cyclic loading conditions. Due to these cyclic loading conditions, the nodal regions (hot areas) are under highly stressed, and the relevant temperature field is consequently determined. The results obtained from the simulation, and experimental results were found to be close to each other and an error of 2% was noticed. Other welding components are also fabricated such as anvil, specimen-holder and backing plate for producing a satisfactory weld. Meanwhile, the complex mechanism behind the USMW has been addressed and modelled analytically. This model can predict the forces as well as temperatures those occur during the welding process and also explains the effects of various material properties and surface conditions on the weld behaviour. The experiments have been performed on the aluminium, copper, brass and stainless steel metal sheets with a number of different configurations, anvil designs, and surface conditions. The fundamental aspect of this study is to control the process parameters like vibration amplitude, weld pressure and weld time so that, an appreciable weld strength can be obtained. Thus, tensile shear and T-peel failure load studies suggest that increase in vibration amplitude means the increase of scrubbing action between the faying surfaces, resulting a better bonding strength. Similarly, increase in weld pressure also increases these weld failure loads and reach a peak value at a particular pressure. But, subsequently, these failure loads decrease due to suppression of relative motion between sheets and initiation of cracks. Excessive weld time also causes cracks around the weld spot. Likewise, if the thickness of the sheets increased, weld strengths are also increased due to absorption of more amount of ultrasonic energy. Moreover, the highest weld interface temperatures and weld areas are observed at the end of weld time because of the larger plastic deformation at the mating surfaces. For all the experiments, first anvil design shows maximum failure loads due to its non-cutting width and angle of knurls. Likewise, on the increase of surface roughness, the tensile shear, and T-peel failure loads decrease. It is found that, in lubricating condition, the highest failure loads are obtained. Furthermore, the polynomial regression, artificial neural network (ANN) and adaptive neuro-fuzzy inference system (ANFIS) methods are developed and compared for each performance measure so that the whole welding process can be accurately described by a best predictive model. A welding mechanics based numerical model has been developed which can predict the temperatures during USMW process for various surface conditions. For all the experimental investigations, the predictive results show good agreement with the experimental values. In addition to it, acoustic softening during ultrasonic welding is found to very significant for the reduction in yield strength of the weld material up to 95 %. It is seen that the quality of welding depends on the material properties, process parameters, and thickness of the workpiece. The present investigation also explains in details the effect of process parameters on the responses through metallurgical analysis. A quality lobe of welding like “under weld”, “good weld” and “over weld” is proposed after observing the fractured samples in optical microscopy and scanning electron microscopy (SEM). Meantime, energy dispersive spectroscopy (EDS) and X- ray diffraction (XRD) analyses are also used to reveal the thickness of interatomic diffusion and IMCs along the weld interface

Technical management of vlcc/vlbc hull structures based on safety case principles

Recent high profile accidents involving environmental damage caused by structural failures in ageing oil tankers and bulk carriers has highlighted the importance of structural integrity issues involving these types of ships. Between 1980 and 1996, there were 186 total losses of bulk and combination carriers and 1,278 lives lost. These events have led to concerns from the public, media and within the international maritime community, about deteriorating ship structural safety standards and the environmental impact. Evidence suggests that structural failure may account for more ship losses than hitherto believed. Industry critics have complained that the quality of designs for new tonnage and effectiveness of the present control mechanisms governing structural condition for vessels in service, are inadequate. Due to the relatively low safety margins inherent in modern commercial ship structural designs, a buyer beware policy prevails in ship procurement. A weakness in current ship design practice appears to be the difficulty of incorporating an owner's individual preferences. Recognising that to be effective, improvements in ship structural design must be implemented at the design stage, this study addresses the challenge of further improving the structural safety and performance of large bulk ships through exercising specific options related to the structural design of the ship within the remit of the buyer. A broad comprehensive literature survey was conducted to cast a wide net around the problem. The complex web of regulatory controls affecting the design and operation of bulk ship hull structures was analysed and problems involving design, construction and maintenance of these vessels were uncovered to build evidence to justify proposing an improved method. An analysis of recent high profile tanker and bulk carrier accidents involving structural failure was performed, to determine root causes. These findings formed the basis for a proposed novel risk-based "design for safety" framework The core of the method is the new evidential reasoning (ER) algorithm developed on the basis of a MCDA evaluation framework and the evidence combination rule of the Dempster-Shafer (D-S) Theory. A number of structural design options focused on the cargo tank mid body area of a typical double hull VLCC were evaluated. A set of quantitative and qualitative criteria were identified and articulated, leading to a structural evaluation framework for eliciting preferences for competing options. The MCDAlER model provides a risk-based, rational, transparent methodology for rapid techno-economic evaluation of alternative structural designs, putting buyers in a stronger position to balance risks and determine the expected structural safety outcomes of different designs. The ER modelling is performed using the Intelligent Decision System (IDS) software program developed by Yang and Xu. The method was tested with an example and validated through a sensitivity study. Finally, the evidence necessary for constructing and demonstrating the MCDAlER structural evaluation framework was used to build the arguments for a safety case approach to hull structures using the Australian Offshore safety case model. The safety case for hull structures is built upon a foundation of existing prescriptive statutory and classification society structural regulatory requirements. The advantages of the safety case applied to oil tankers were explained, including suggestions for a new regulatory approach. The application of new technology and tools was discussed