Multiaxial Fatigue Assessment of Friction Stir Welded Tubular Joints of Al 6082-T6

The present paper addresses the problem of designing aluminium friction stir (FS) welded joints against multiaxial fatigue. After developing a bespoke FS welding technology suitable for joining aluminium tubes, some one hundred welded tubular specimens of Al 6082-T6 were tested under pure axial, pure torsional and biaxial tension-torsion loading. The influence was explored of two independent variables, namely the proportional or nonproportional nature of the biaxial loading and the effect of axial and torsional non-zero mean stresses. The experimental results were re-analysed using the Modified Wöhler Curve Method (MWCM), with this bi-parametrical critical plane approach being applied in terms of nominal stresses, notch stresses, and also the Point Method. The validation exercise carried out using these experimental data demonstrated that the MWCM is applicable to prediction of the fatigue lives for these FS welded joints, with its use resulting in life estimates that fall within the uniaxial and torsional calibration scatter bands. The approach proposed in the present paper offers, for the first time, a complete solution to the problem of designing tubular FS welded joints against multiaxial fatigue loading

Sulla stima della vita a fatica di giunti saldati soggetti a carichi multiassiali ad ampiezza variabile

Nel presente articolo viene proposta una nuova metodologia di progettazione a fatica, basata sull’utilizzo del metodo delle Curve di Wöhler Modificate, per la previsione della vita a fatica di giunzioni saldate, sia in acciaio che in alluminio, soggette a carichi multiassiali ad ampiezza variabile. In particolare, il criterio delle Curve di Wöhler Modificate è stato applicato determinando l’orientazione del piano critico mediante il Metodo della Massima Varianza, ovvero definendo il piano critico come quello contenente la direzione che sperimenta la massima varianza della tensione tangenziale risolta. L’accuratezza della metodologia di progettazione a fatica proposta nella presente memoria è stata valutata mediante due serie di dati sperimentali di letteratura ottenute sollecitando, sia ad ampiezza costante che variabile, giunti saldati tubo-piastra in acciaio e lega di alluminio con carichi di flesso/torsione in fase e sfasati di 90°. Il criterio delle Curve di Wöhler Modificate, applicato in concomitanza con il Metodo della Massima varianza, si è dimostrato capace di fornisce stime accurate della durata a fatica anche in presenza di sollecitazioni multiassiali ad ampiezza variabile, e questo sia quando applicato in termini di tensioni nominali che in termini di tensioni di “hot-spot”

POM@PMO plastic electrode for phosphate electrochemical detection: a further improvement of the detection limit

The development of a highly sensitive electrochemical sensor (E-sensor) is described based on stand-alone plastic electrodes (PE) for phosphate detection, being an essential nutrient in the marine environment. The detection mechanism is based on the chemical affinity between polyoxomolybdate anions (POM) and orthophosphate to form an electroactive phosphomolybdate complex. The custom-made E-sensor was formulated with an organic octamolybdate derivative (TBA4Mo8O26) incorporated with periodic mesoporous organosilica (PMO) to obtain a significant improvement in the analytical performances of phosphate determination. This POM@PMO combination was found to be advantageous in the determination of low concentrations of phosphate in standard solutions ranging from 1 to 500 nM, using square wave voltammetry as the detection technique. This sensitivity enhancement can be attributed to the effect of hydrophobic PMO in loading more POM moieties, owing to its highly porous structure and charged shell. Consequently, the POM@PMO-PE sensor achieved a competitive sensitivity of 4.43 ± 0.14 μA.nM−1.cm−2 and a limit of detection of 0.16 nM with good selectivity against silicates. Finally, seawater and treated wastewater samples have been tested to validate the sensor response in comparison to the official method of phosphate determination. Graphical abstract: [Figure not available: see fulltext.

Crack Paths in Sharply Notched Specimens under In-Phase Biaxial Loadings

ABSTRACT. In this paper crack paths have been studied in sharply

Sulla stima della vita a fatica di giunti saldati soggetti a carichi multiassiali ad ampiezza variabile

Nel presente articolo viene proposta una nuova metodologia di progettazione a fatica, basata sull’utilizzo del metodo delle Curve di Wöhler Modificate, per la previsione della vita a fatica di giunzioni saldate, sia in acciaio che in alluminio, soggette a carichi multiassiali ad ampiezza variabile. In particolare, il criterio delle Curve di Wöhler Modificate è stato applicato determinando l’orientazione del piano critico mediante il Metodo della Massima Varianza, ovvero definendo il piano critico come quello contenente la direzione che sperimenta la massima varianza della tensione tangenziale risolta. L’accuratezza della metodologia di progettazione a fatica proposta nella presente memoria è stata valutata mediante due serie di dati sperimentali di letteratura ottenute sollecitando, sia ad ampiezza costante che variabile, giunti saldati tubo-piastra in acciaio e lega di alluminio con carichi di flesso/torsione in fase e sfasati di 90°. Il criterio delle Curve di Wöhler Modificate, applicato in concomitanza con il Metodo della Massima varianza, si è dimostrato capace di fornisce stime accurate della durata a fatica anche in presenza di sollecitazioni multiassiali ad ampiezza variabile, e questo sia quando applicato in termini di tensioni nominali che in termini di tensioni di “hot-spot”

Static assessment of brittle/ductile notched materials: an engineering approach based on the Theory of Critical Distances

Engineering components often contain notches, keyways or other stress concentration features. These features raise the stress state in the vicinity of their apex which can lead to unexpected failure of the component. The Theory of Critical Distances has been proven to predict accurate results, but, conventionally, requires two key ingredients to be implemented: the first is a stress-distance curve which can be obtained relatively easily by means of any finite element software, the second is two additional material parameters which are determined by running appropriate experiments. In this novel reformulation, one of these additional parameters, namely the critical distance, can be determined a priori, allowing design engineers to assess components whilst reducing the time and cost of the design process. This paper investigates reformulating the Theory of Critical Distances to be based on two readily available material parameters, i.e., the Ultimate Tensile Strength and the Fracture Toughness. An experimental data base was compiled from the technical literature. The investigated samples had a range of stress concentration features including sharp V-notches to blunt U-notches, and a range of materials that exhibit brittle, quasi-brittle and ductile mechanical behaviour. Each data set was assessed and the prediction error was calculated. The failure predictions were on average 30% conservative, whilst the non-conservative predictions account for less than 10% of the tested data and less than 2% of the non-conservative error results exceed -20%. It is therefore recommended that a safety factor of at least 1.2 is used in the implementation of this version of the Theory of Critical Distances

A variable amplitude fretting fatigue life estimation technique: formulation and experimental validation

The aims of the research work summarised in this paper are twofold. The first goal is to make available a large number of new experimental results generated by testing specimens of grey cast iron under both constant and variable amplitude fretting fatigue loading. The second goal is to formulate an advanced fretting fatigue design approach based on the combined use of the Modified Wӧhler Curve Method, the Theory of Critical Distances and the Shear Stress-Maximum Variance Method. The validation exercise based on the experimental results being produced demonstrates that the proposed methodology is a powerful tool suitable for designing mechanical assemblies against fretting fatigue

Multiaxial fatigue of aluminium friction stir welded joints: Preliminary results

The aim of the present research is to check the accuracy of the Modified Wöhler Curve Method (MWCM) in estimating the fatigue strength of friction stir (FS) welded tubular joints of Al 6082-T6 subjected to in-phase and out-of-phase multiaxial fatigue loading. The welded samples being investigated were manufactured by equipping an MTS I-STIR process development system with a retracting tool that was specifically designed and optimised for this purpose. These specimens were tested under proportional and non-proportional tension and torsion, the effect of non-zero mean stresses being also investigated. The validation exercise carried out by using the generated experimental results allowed us to prove that the MWCM (applied in terms of nominal stresses) is highly accurate in predicting the fatigue strength of the tested FS welded joints, its usage resulting in estimates falling with the uniaxial and torsional calibration scatter bands

Fatigue behaviour of Al 6082-T6 friction stir welded tubular joints under torsional loading

The aim of the present research is to investigate the fatigue behaviour of friction stir (FS) welded tubular joints in aluminium alloy subjected to torsional fatigue loading. To manufacture the samples which were tested, an MTS I-STIR process development system was equipped with a retracting tool specifically designed for these tubular welds. Al 6082-T6 FS welded samples were tested under cyclic torsion with a nominal shear stress ratio equal to-1 and 0. The test data show that, strictly speaking, the presence of non-zero mean shear stresses has a detrimental effect on the overall torsional fatigue strength of the FS welded joints. However, the reanalysis discussed in the present paper suggests that, from a statistical point of view, any detrimental effect is small. This means that fatigue assessment under torsional fatigue loading of these FS welded tubular connections can be performed with little loss of accuracy by neglecting the presence of non-zero mean shear stresses