Freeze-Thaw Durability and Long-Term Performance Evaluation of Shotcrete in Cold Regions

This study’s aim was to evaluate the freeze-thaw durability of shotcrete in cold regions and predict its long-term performance. One benchmark mix design from the WSDOT was chosen to prepare samples for performance evaluation. Shotcrete specimens were conditioned in accordance with ASTM C666. The long-term freeze-thaw performance after certain cycles was evaluated using the dynamic modulus of elasticity test (ASTM C215), fracture energy test (RILEM 50-FMC), and X-ray CT microstructure imaging analysis. Probabilistic damage analysis was conducted to establish the relation between the durability life and the damage parameter for different probabilities of reliability using the three-parameter Weibull distribution model. The fracture energy test was found to be a more sensitive test method than the dynamic modulus of elasticity for screening material deterioration over time and for capturing accumulative material damage caused by rapid freeze-thaw action, because of smaller durability factors (degradation ratios) obtained from the fracture energy test. X-ray CT imaging analysis is capable of detecting microcracks that form and pore evolution in the aggregate and interface transition zone of conditioned samples. Moreover, the continuum damage mechanic-based model shows potential in predicting long-term material degradation and the service life of shotcrete

Quantitative ultrasonic evaluation of engineering properties in metals, composites and ceramics

Ultrasonic technology from the perspective of nondestructive evaluation approaches to material strength prediction and property verification is reviewed. Emergent advanced technology involving quantitative ultrasonic techniques for materials characterization is described. Ultrasonic methods are particularly useful in this area because they involve mechanical elastic waves that are strongly modulated by the same morphological factors that govern mechanical strength and dynamic failure processes. It is emphasized that the technology is in its infancy and that much effort is still required before all the available techniques can be transferred from laboratory to industrial environments

Magnetic Barkhausen emission analysis for assessment of microstructures and damage

Application of magnetic Barkhausen emission (MBE) analysis for assessment of microstructures and damage in various materials including carbon steel, Cr-Mo ferritic steels, 17-4 PH steel and metastable austenitic stainless steel. Thermally-induced microstructural changes in Cr-Mo steels have been correlated with MBE, based on a two-stage magnetisation process model. The MBE parameters have also been used to characterise different stages of tensile deformation and to assess tensile strength. Charpy impact energy, quality of induction hardening process, progress of carburisation in reformer tubes and fatigue damage

Surface factor assessment in HCF for steels by means of empirical and non destructive techniques

The fatigue limit value in steels is strongly influenced by many factors, among them the surface finish. In particular, the fatigue limit decreases with increasing the surface roughness, referring to standard grinded specimen.Technical literature provides an empirical correction factor, named surface factor, to be used if surface roughness is different from standard specimen conditions. This factor is traditionally lower than 1 and it reduces the fatigue limit value corresponding to the material in standard conditions. This coefficient may be obtained from literature graphs and it can be identified by means of two parameters: materials ultimate tensile strength and surface finish Ra.Aim of the present paper is to evaluate the effectiveness of fast procedures to assess the surface factor. The reference is the Murakami model, which estimates the fatigue limit by means of roughness parameters other than Ra.In the present paper the fatigue limit estimations related to specimens with sanded Rahave been obtained by utilizing empirical destructive and nondestructive methods and then have been compared each other.Experimental testing was carried out on a structural steel specimens by means of axial alternate fatigue testing with two different surface roughness.The results obtained referring to Murakami model have been compared with those obtained by means of both thermographic and Staircase method.The Murakami model results to be easy to use and non destructive.The corresponding fatigue limit estimations match with the thermographic ones above all when surface roughness is elevated

The present state of surface conditioning in cutting and grinding

All manufacturing processes have an impact on the surface layer state of a component, which in turn significantly determines the properties of parts in service. Although these effects should certainly be exploited, knowledge on the conditioning of the surfaces during the final cutting and abrasive process of metal components is still only extremely limited today. The key challenges in regard comprise the process-oriented acquisition of suitable measurement signals and their use in robust process control with regard to the surface layer conditions. By mastering these challenges, the present demands for sustainability in production on the one hand and the material requirements in terms of lightweight construction strength on the other hand can be successfully met. In this review article completely new surface conditioning approaches are presented, which originate from the Priority Program 2086 of the Deutsche Forschungsgemeinschaft (DFG)

Use of Energy Consumption during Milling to Fill a Measurement Gap in Hybrid Additive Manufacturing

Coupling additive manufacturing (AM) with interlayer peening introduces bulk anisotropic properties within a build across several centimeters. Current methods to map high resolution anisotropy and heterogeneity are either destructive or have a limited penetration depth using a nondestructive method. An alternative pseudo-nondestructive method to map high-resolution anisotropy and heterogeneity is through energy consumption during milling. Previous research has shown energy consumption during milling correlates with surface integrity. Since surface milling of additively manufactured parts is often required for post-processing to improve dimensional accuracy, an opportunity is available to use surface milling as an alternative method to measure mechanical properties and build quality. The variation of energy consumption during the machining of additive parts, as well as hybrid AM parts, is poorly understood. In this study, the use of net cutting specific energy was proposed as a suitable metric for measuring mechanical properties after interlayer ultrasonic peening of 316 stainless steel. Energy consumption was mapped throughout half of a cuboidal build volume. Results indicated the variation of net cutting specific energy increased farther away from the surface and was higher for hybrid AM compared to as-printed and wrought. The average lateral and layer variation of the net cutting specific energy for printed samples was 81% higher than the control, which indicated a significantly higher degree of heterogeneity. Further, it was found that energy consumption was an effective process signature exhibiting strong correlations with microhardness. Anisotropy based on residual strains were measured using net cutting specific energy and validated by hole drilling. The proposed technique contributes to filling part of the measure gap in hybrid additive manufacturing and capitalizes on the preexisting need for machining of AM parts to achieve both goals of surface finish and quality assessment in one milling operation