Modelling the influence of machined surface roughness on the fatigue life of aluminium alloy

The influence of machined surface roughness on the fatigue life of 7010 aluminium alloy has been investigated. Four-point bending specimen have been machined according to various machining conditions and tested in fatigue. In order to explain the high dependence of SN curves on the surface roughness of the specimen, an approach based on the finite element analysis of measured surface topography is proposed. Surface grooves due to machining are supposed to generate stress concentrations that are so calculated. A model of fatigue life prediction is developed, using this definition of local Kt

Simplified modelling of the behaviour of 3D-periodic structures such as aircraft heat exchangers

In this paper, experimental, analytical and numerical analysis are used to study and model the mechanical behaviour of a heat exchanger core consisting of a 3D-periodic structure. The purpose of the present investigation is not only to acquire knowledge on the mechanical behaviour of a given heat exchanger core but also to propose a simplified approach to model this behaviour. An experimental study is carried out in order to get an insight on the mechanical behaviour of this structure. Global static characteristics are obtained via analytical and finite element analysis of a unit cell of the core. Dynamic behaviour is studied by means of finite element calculations based on the results of the static modelling. The proposed approach is validated by comparison with experimental tests results

SPH method applied to high speed cutting modelling

The purpose of this study is to introduce a new approach of high speed cutting numerical modelling. A Lagrangian smoothed particle hydrodynamics (SPH)- based model is arried out using the Ls-Dyna software. SPH is a meshless method, thus large material distortions that occur in the cutting problem are easily managed and SPH contact control permits a "natural" workpiece/chip separation. The developed approach is compared to machining dedicated code results and experimental data. The SPH cutting model has proved is ability to account for continuous to shear localized chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Thus, comparable results to machining dedicated codes are obtained without introducing any adjusting numerical parameters (friction coefficient, fracture control parameter)

Black anodic coatings for space applications: study of the process parameters, characteristics and mechanical properties

Black inorganic anodized aluminium alloys are used for managing passive thermal control on spacecraft and for avoiding stray light in optical equipment. Spalling of these coatings has sometimes been observed after thermal cycling on 2XXX and 7XXX aluminium alloys. This phenomenon could generate particulate contamination in satellites and may affect mission lifetime. In this work, the influences of the four main steps of the process (pretreatments, sulphuric anodizing, colouring and sealing) on the coating characteristics have been studied for a 7175 T7351 aluminium alloy. The chemical heterogeneity of the coating has been underlined, and its mechanical behaviour observed through crazing. Scratch-testing, used to evaluate coating adhesion to its substrate, revealed the negative impact of thermal cycling

A predictive fatigue life model for anodized 7050 aluminium alloy

The objective of this study is to predict fatigue life of anodized 7050 aluminum alloy specimens. In the case of anodized 7050-T7451 alloy, fractographic observations of fatigue tested specimens showed that pickling pits were the predominant sites for crack nucleation and subsequent failure. It has been shown that fatigue failure was favored by the presence of multiple cracks. From these experimental results, a fatigue life predictive model has been developed including multi-site crack consideration, coalescence between neighboring cracks, a short crack growth stage and a long crack propagation stage. In this model, all pickling pits are considered as potential initial flaws from which short cracks could nucleate if stress conditions allow. This model is built from experimental topography measurements of pickled surfaces which allowed to detect the pits and to characterize their sizes (depth, length, width). From depth crack propagation point of view, the pickling pits are considered as stress concentrator during the only short crack growth stage. From surface crack propagation point of view, machining roughness is equally considered as stress concentrator and its influence is taken into account during the all propagation stage. The predictive model results have been compared to experimental fatigue data obtained for anodized 7050-T7451 specimens. Predictions and experimental results are in good agreement

Surface characterization and influence of anodizing process on fatigue life of Al 7050 alloy

The present study investigates the influence of anodizing process on fatigue life of aluminium alloy 7050-T7451 by performing axial fatigue tests at stress ratio ‘R’ of 0.1. Effects of pre-treatments like degreasing and pickling employed prior to anodizing on fatigue life were studied. The post-exposure surface observations were made by scanning electron microscope (SEM) to characterize the effect of each treatment before fatigue testing. The surface observations have revealed that degreasing did not change the surface topography while pickling solution resulted in the formation of pits at the surface. Energy dispersive spectroscopy (EDS) was used to identify those constituent particles which were responsible for the pits formation. These pits are of primary concern with respect to accelerated fatigue crack initiation and subsequent anodic coating formation. The fatigue test results have shown that pickling process was detrimental in reducing the fatigue life significantly while less decrease has been observed for anodized specimens. Analyses of fracture surfaces of pickled specimens have revealed that the process completely changed the crack initiation mechanisms as compared to non-treated specimens and the crack initiation started at the pits. For most of the anodized specimens, fatigue cracks still initiated at the pits with very few cracks initiated from anodic coating. The decrease in fatigue life for pickled and anodized specimens as compared to bare condition has been attributed to decrease in initiation period and multi-site crack initiations. Multi-site crack initiation has resulted in rougher fractured surfaces for the pickled and anodized specimens as compare to bare specimens tested at same stress levels

Etats de surface - Matériaux de surface : Résistance à l'endommagement

Les travaux de recherche présentés dans ce mémoire s’articulent autour des interactions entre surface et endommagement. La première partie concerne l’influence du procédé d’usinage sur la tenue en fatigue d’un alliage d’aluminium aéronautique. La deuxième partie est dédiée à l’étude de l’endommagement d’origine thermique d’un traitement de surface par anodisation sur alliage d’aluminium. Enfin, l’objet de la dernière partie est d’étudier la possibilité de caractériser le comportement en fissuration par fatigue d’éprouvettes de très faibles épaisseurs afin de se rapprocher au plus près de la « surface » endommagée

Étude thermomécanique d’une nouvelle géométrie d’éprouvette de fatigue en environnement sévère

De nombreuses pièces mécaniques sont soumises à des variations de chargement dans des environnements agressifs. Pour évaluer la tenue des matériaux les constituant, a été développée une nouvelle géométrie d’éprouvette. Il s’agit d’une éprouvette tubulaire, dont le fût constitue la zone utile, munie d’un noyau fabriqué dans le même matériau qui fait office de demi ligne. Dans cet article, sera présenté le bon comportement mécanique de cette éprouvette en fatigue et en flambage. Pour vérifier ce dernier point, un modèle tridimensionnel complet a été réalisé. Les résultats étant concluants, l’étude du comportement en cyclage thermique a débuté. Un modèle a été développé au moyen d’un code par éléments finis qui montre des gradients inférieurs à 40K pour des amplitudes de cyclage de l’ordre de 850 K. Ce modèle une fois validé expérimentalement permettra d’optimiser le système d’essai pour minimiser les gradients tout en augmentant la fréquence des cycles thermiques

Surface integrity after pickling and anodization of Ti–6Al–4V titanium alloy

The surface integrity of Ti–6Al–4V titanium alloy was studied at different stages of surface treatments, especially pickling and compact anodization, through surface characteristics potentially worsening fatigue resistance. No significant changes of the equiaxe microstructure were detected between sample core and surface, or after the pickling and anodization steps. Surface hydrogen and oxygen superficial contents were found to remain unchanged. Roughness characteristics (i.e. Ra, Rz but also local Kt factor) similarly showed only slight modifications, although SPM and SEM revealed certain random local surface defaults, i.e. pits about 400 nm in depth. Finally internal stresses, evaluated using X-ray diffraction, highlighted a significant decrease of the compressive internal stresses, potentially detrimental for fatigue resistance

Investigations into the coefficient of thermal expansion of porous films prepared on AA7175 T7351 by anodizing in sulphuric acid electrolyte

The aim of this study was to investigate the Coefficient of Thermal Expansion (CTE) of anodic films on 7175 T7351 aluminium alloy and to evaluate the influence of the film characteristics on this value. In particular, effects of porosity and post-treatments, such as coloring and sealing, were studied. Beam bending analysis was used as the experimental method and a numerical finite element model was developed to verify theoretical relationships hypotheses. The values determined and the choice of experimental method were then validated by comparing the experimental cracking temperature of anodic films with a theoretical value directly depending on the previously determined CTE