Experimental and numerical investigation of residual stress effects on fatigue crack growth behaviour of S355 steel weldments

Fatigue crack growth tests have been conducted on S355 G10+M structural steel which is widely used in the fabrication of offshore structures. Fracture mechanics tests have been performed on compact tension specimens with the crack tip located in the heat affected zone. All tests were performed at room temperature in air and the obtained results are compared with the literature data available on a range of offshore structural steels and also the recommended BS7910 trends using the 2-stage law and simplified law. The specimen orientation, with respect to the location of the extraction within the welded plate, has also been examined and discussed in this work. Residual stress measurements have been performed prior to testing by using the neutron diffraction technique. Finally, a numerical model has been developed in order to calculate the effective stress intensity factor range in the presence of residual stresses. The results have shown that the residual stresses play a key role in the fatigue life of the welded structures, especially in the near threshold regio

Energy-resolved neutron imaging for reconstruction of strain introduced by cold working

Energy-resolved neutron transmission imaging is used to reconstruct maps of residual strains in drilled and cold-expanded holes in 5-mm and 6.4-mm-thick aluminum plates. The possibility of measuring the positions of Bragg edges in the transmission spectrum in each 55 × 55 µm2 pixel is utilized in the reconstruction of the strain distribution within the entire imaged area of the sample, all from a single measurement. Although the reconstructed strain is averaged through the sample thickness, this technique reveals strain asymmetries within the sample and thus provides information complementary to other well-established non-destructive testing methods

Development of process induced residual stress during flow forming of tubular 15-5 martensitic stainless steel

Flow forming is a near net shape process for manufacturing of dimensionally accurate hollow components such as shaft in gas turbines, that is currently at its development stage for aerospace industry. The process has several advantages such as reducing material wastage, extremely fast manufacturing time, and eliminating extra manufacturing processes such as machining. Due to the nature of this complicated cold deformation process, significant magnitude of residual stress is introduced into the component. Understanding the magnitude and distribution of residual stress is essential to tailor the flow forming process to achieve parts within dimensional tolerances and desired mechanical properties. The present research is aiming to explore the generation and evolution of residual stress at various stages of flow forming process in a tubular component made from martensitic 15Cr-5Ni stainless steel, using different techniques of neutron scattering, x-ray diffraction (XRD) and hole-drilling based on electronic speckle pattern interferometry (ESPI). Residual stress measurements were carried out in pre-formed and flow formed components at surface, near-surface and in the bulk of components using XRD, ESPI based hole-drilling and neutron diffraction techniques. These measurements were conducted at different levels of reduction in the thickness of the original part (i.e. after 20% and 40%), by applying identical forming parameters for all samples. The XRD results show significant change in hoop and axial residual stress levels with a reduction in the wall thickness. This is more pronounced for the axial component where the average stress switches from relatively high tensile (~ 450MPa) in the original part to significant compressive stress (~ -600MPa) in the formed part, after 20% of reduction. The bulk residual stress components measured in the middle of thickness of the parts, using neutron scattering, show a general increase in the magnitude of residual stress by higher level of deformation (i.e. reduction in the wall thickness). The measured bulk stress components through the thickness were tuned to tensile after reducing the wall thickness by 40%. The results of XRD and neutron diffraction stress measurements suggest that the residual stress along the length of the samples (i.e. axial direction) is consistent with ±800 MPa and ±400 MPa after 20% and 40% reduction by forming process, respectively. The results of ESPI based hole-drilling show tensile hoop residual stress (≈600 MPa) and an abrupt fluctuation (i.e. tension-compressive-tension) in the axial residual stress near the surface of the part following flow forming. The stresses measured by ESPI based hole-drilling are complementary to the results of the XRD on surface and neutron diffraction in the bulk to reconstruct the residual stress profile form the surface through to the bulk

Effect of stress on NiO reduction in solid oxide fuel cells: A new application of energy-resolved neutron imaging

Recently, two new phenomena linking stress field and reduction rates in anode supported solid oxide fuel cells SOFCs have been demonstrated, so called accelerated creep during reduction and reduction rate enhancement and nucleation due to stress Frandsen et al., 2014 . These complex phenomena are difficult to study and it is demonstrated here that energy resolved neutron imaging is a feasible technique for combined mechanics chemical composition studies of SOFC components, including commercially produced ones. Cermet anode supports, which prior to the measurements were reduced under varying conditions such as different temperatures, various times and different values of applied stress, have been measured. Thus, samples with different contents and gradients of Ni and NiO phases were investigated. The first Bragg edge transmission neutron measurements applied for the studies of the reduction progress in these samples were performed at two neutron beamline facilities ISIS in the UK, Helmholtz Zentrum Berlin in Germany . The obtained results demonstrate the possibility to image and distinguish NiO and Ni phases within SOFC anode supports by energy resolved neutron imaging and the potential of the neutron imaging method for in situ studies of reduction processe

Power inside - applications and technologies for integrated power in microelectronics

The emergence of miniaturized and integrated Power Supply on Chip (PwrSoC) and Power Supply in Package (PwrSiP) platforms will be enabled by the application of thin-film, integrated magnetics on silicon. A process flow for, and the design of, a thin-film coupled-inductor, switching at 60MHz, is described. Based on the large signal characterization data, measured up to 100MHz, the efficiency of the inductor is calculated to be 91.7% for a power of 0.5W

Integrated microinductors on semiconductor substrates for power supply on chip (Invited)

Microinductors were fabricated using electrodeposition for integration on semiconductor substrates. The process was optimised through validated models developed to focus on efficiency and footprint. Lithographic processing was performed to microfabricate Cu coils over a magnetic core. A racetrack design was used to maximise the high frequency response, yielding high inductance density and low DC resistance. The magnetic core was subsequently closed using a magnetic thin film deposition over a dielectric deposited on the Cu coils. Homogeneous ferromagnetic alloy, Ni45Fe55 of uniform thickness over a high aspect-ratio 3D structure has been achieved. Ni45Fe55 was chosen for the fabrication of micromagnetic cores due to its relatively high saturation flux density (1.6 T), resistivity (48 mΩ cm) and anisotropy field (9.5 Oe). The rationale, design, microfabrication process and characterisation results are presented

Venous thromboembolism in children with cancer – a population-based cohort study

Introduction: Cancer is a known risk factor for venous thromboembolism (VTE) in adults, but population-based data in children are scarce. Materials and methods: We conducted a cohort study utilising linkage of the Clinical Practice Research Database (primary care), Hospital Episodes Statistics (secondary care), UK Cancer Registry data and Office for National Statistics cause of death data. From these databases, we selected 498 children with cancer diagnosed between 1997 and 2006 and 20,810 controls without cancer. We calculated VTE incidence rates in children with cancer vs. controls, and hazard ratios (HRs) using Cox regression. Results: We identified four VTE events in children with cancer compared with four events in the larger control population corresponding to absolute risks of 1.52 and 0.06 per 1000 person-years respectively. The four children with VTE and cancer were diagnosed with hematological, bone or non-specified cancer. Childhood cancer was hence associated with a highly increased risk of VTE (HR adjusted for age and sex: 28.3; 95%CI = 7.0-114.5). Conclusions: Children with cancer are at increased relative risk of VTE compared to those without cancer. Physicians could consider thromboprophylaxis in children with cancer to reduce their excess risk of VTE however the absolute risk is extremely small and the benefit gained therefore would need to be balanced against the risk invoked of implementing such a strategy. Novelty & Impact Statements: While there is a reasonable level of knowledge about the risk of VTE in adult populations, it is not well known whether this risk is reflected in paediatric patients. We found a substantial increase in risk of VTE in children with cancer compared to a child population without cancer. While this finding is important, the absolute risk of VTE is still low and must be balanced with the risks of anticoagulation

High frequency DC-DC converter with co-packaged planar inductor and power IC

The paper introduces the trend of integration and miniaturization of power converters with potential for enhanced efficiency, form factor reduction and cost reduction. To demonstrate the concept of highly integrated switched mode power supply with integrated magnetic, a system-in-package DC-DC converter using a stacked co-packaging approach is developed. A system approach was taken to the design, and functional integration, using 3-D packaging for realizing a power supply in package solution (PwrSiP). The target integrated converter is capable of handling an input voltage of 5V and frequencies up to 40MHz. A DC-DC converter IC on a 0.35μm CMOS process was designed to meet this goal. In parallel with the IC design, technology development for on-silicon integrated micro-inductors was completed to achieve small-form factor and extremely low profile. A maximum measured efficiency of 83% and 78% was achieved on the stacked converter operating at 20MHz and 40MHz, respectively. The stacked approach showed a 30% area reduction compared to side-by-side implementation with external discrete inductor