Influence of the microstructure on fatigue and fracture toughness properties of large heat-treated mold steels

The standard ISO 1.2738 medium-carbon low-alloy steel has long been used to fabricate plastic molds for injection molding of large automotive components, such as bumpers and dashboards. These molds are usually machined from large pre-hardened steel blooms. Due to the bloom size, the heat treatment yields mixed microstructures, continuously varying from surface to core. Negative events (such as microcracks due to improper weld bed deposition or incomplete extraction of already formed plastic objects) or too large thermal/mechanical stresses can conceivably cause mold failure during service due to the low fracture toughness and fatigue resistance typically encountered in large slack quenched and tempered ISO 1.2738 steel blooms. Alternative steel grades, including both non-standard microalloyed steels, designed for the same production process, and precipitation hardening steels, have recently been proposed by steelworks. However, the fracture toughness and the fatigue properties of these steels, and hence their response during the service, are not well known. Results of an experimental campaign to assess the fracture toughness and fatigue properties, as well as the basic mechanical properties, of a microalloyed and a precipitation hardening plastic mold steel blooms are presented and commented, also in respect to the results previously obtained by two commercial ISO 1.2738 ones. Experimental results show that these steels generally exhibit low fracture toughness values; in the traditional quenched and tempered bloom steels the brittleness may be caused both by the presence of mixed microstructures and by grain boundaries segregation, while in the precipitation hardened one the brittleness probably stems from the precipitation phenomena. This study suggests that microalloyed and precipitation hardening steels may be used to produce large plastic mold, yet the fracture toughness still remains the most critical propert

An extension of the Equivalent Material Concept applied to fracture of U-notched solids

ABSTRACT: The Equivalent Material Concept is a tool that allows the fracture behavior of notched components in elastoplastic materials to be analyzed by transforming them into fictitious linear elastic ones, defining a fictitious failure stress. The combination of a failure criterion with this approach offers a methodology for predicting the maximum load of notched solids with elastoplastic behavior.The validity limits have been established experimentally by a logistic regression using fracture data of linear elastic, small scale yielding and fully plastic material. This paper also proposes an extension of the Equivalent Material Concept, applying the fictitious transformation in a more complete form to tensile, toughness and notch tests. New magnitudes as the fictitious stress, the fictitious toughness and the fictitious notch stress intensity factors have been defined. The final proposal is a partial application of the fictitious transformation that incorporates all of the experimental data gathered.The authors wish to express their gratitude to the European Union’s H2020 research and innovation program for their financial support under the LightCoce project (No 814632)

On the Mechanistic Origins of Toughness in Bone

One of the most intriguing protein materials found in nature is bone, a material composed of assemblies of tropocollagen molecules and tiny hydroxyapatite mineral crystals that form an extremely tough, yet lightweight, adaptive and multifunctional material. Bone has evolved to provide structural support to organisms, and therefore its mechanical properties are of great physiological relevance. In this article, we review the structure and properties of bone, focusing on mechanical deformation and fracture behavior from the perspective of the multidimensional hierarchical nature of its structure. In fact, bone derives its resistance to fracture with a multitude of deformation and toughening mechanisms at many size scales ranging from the nanoscale structure of its protein molecules to the macroscopic physiological scale.United States. Army Research Office (contract number W911NF-06-1-0291)National Science Foundation (U.S.) (CAREER award (contract number 0642545))Lawrence Berkeley National Laboratory (Laboratory Directed Research and Development Program)United States. Dept. of Energy (Office of Science, Office of Basic Energy Sciences, Division of Materials Sciences and Engineering, contract number DE-AC02-05CH11231

Structural integrity assessment of the welded joints of the constitution of 1812 bridge (Cádiz, Spain)

As required by the current Spanish regulations, an inspection and maintenance plan has been completed for the Constitution of 1812 Bridge over the Bay of Cádiz (Spain), which defines the work to be performed on the different elements of the bridge during its service life. The part of the plan related to the inspection of the steel structure has a section dedicated to the inspection of the defects that may be present in the welded joints of the steel deck, providing critical defect sizes above which the safety of the structure would be compromised. With this purpose, in the most stressed points of the deck, the structural details that are most susceptible to fatigue and fracture phenomena have been identified. Moreover, fatigue tests of these details have been performed to complete a structural integrity assessment that also comprises the determination of the material fracture toughness and the definition of the corresponding critical crack sizes. The tests were carried out on specimens obtained with the same steel grades as those used in the bridge and with the same welding procedures as those practiced in the structure. The results show that the fatigue test results are above the SN curves provided by the Eurocode 3, and also that numerous critical crack sizes would not be detected by the usual inspection techniques used in bridges (visual inspection), so that further research into how to manage this issue is recommended.The authors of this work would like to express their gratitude to the University of Cantabria for the financial support of the project “Aplicación de Técnicas de Integridad Estructural y Fiabilidad de Materiales en la Determinacion del Ciclo de Vida de Puentes Metalicos y Mixtos- Application of Structural Integrity and Materials Reliability Techniques to the Life-Cycle Assessment of Metallic and Steel-Concrete Composite Bridges” (03.DI09.649), programme of industrial doctorates, on the results of which this paper is based

On the Line Method apparent fracture toughness evaluations: experimental overview, validation and some consequences on fracture assessments

This paper analyses the capacity of the Line Method to provide evaluations of the apparent fracture toughness, which is the fracture resistance exhibited by materials in notched conditions. With this aim, the experimental results obtained in 555 fracture tests are homogeneously presented and compared to the Line Method evaluations. It is remarked that the Line Method provides adequate estimates of the apparent fracture toughness, and also that it conveniently addresses the physics of the notch effect. All this makes the Line Method a valuable scientific and engineering tool for the fracture assessment of materials containing notches