Détermination d'une loi de propagation de fissure de fatigue par corrélation d'images numériques

La Corrélation d'Images Numériques (CIN) a été utilisée pour identifier des lois de propagation de fissures en utilisant comme cadre les séries de Williams. La procédure d'identification est menée en trois étapes : (i) détermination des champs de déplacement sur chaque cycle de chargement considéré; (ii) détermination des termes des séries de Williams par une minimisation de la différence des champs expérimentaux avec les solutions analytiques de Williams paramétrées automatiquement; (iii) les coefficients identifiés sont alors utilisés pour initialiser la troisième étape qui est une corrélation d'images dite « intégrée » où les fonctions de forme sont les séries de Williams. Cette procédure permet d'obtenir des résultats plus précis que par une simple méthode projective et permet de gagner un temps précieux en initialisant les termes des séries de Williams pour la corrélation intégrée

3D X-ray Microtomography Volume Correlation to Study Fatigue Crack Growth

International audienceGlobal digital volume correlation is used to analyze a series of computed tomography images of a nodular graphite cast iron specimen subjected in situ to a fatigue test. From the obtained displacement field, a specific procedure is implemented to extract stress intensity factors all along the crack front. The proposed methodology allows one to measure key parameters in fatigue crack propagation directly from 3D images

Plastic zone evolution during fatigue crack growth: Digital image correlation coupled with finite elements method

International audienceNonlinearities effects at the crack tip, due to the elastic-plastic material behavior , impact the crack growth rate and path. This paper is devoted to the study of the plastic zone evolution in the crack tip region. The methodology relies on coupling an elastic-plastic Finite Elements Method (FEM) model and experimental displacements measured by Digital Image Correlation (DIC). These latter are introduced as Dirichlet boundary conditions in the finite elements analysis. The considered FEM domain is constant, i.e. the same mesh with a centered crack is moved to each new crack tip position deduced from DIC. The new boundary conditions are updated and the residual stresses and plastic strains of the former computation are interpolated and actualized on the mesh shifted to the new crack tip position in order to incorporate them in the numerical model. The coupling method allowed applying experimental boundary conditions in order to be as close as possible to real experimental conditions and to observe the plasticity evolution from small to large scale yielding conditions. A fatigue test was conducted to validate the proposed approach. The identification residues are proved to be lower than those obtained with an experimental displacements projection onto Williams' series basis, which is a method commonly used with DIC. The coupling results present an attractive similarity with Irwin's model regardless of the crack length. Thus, the definition of the mask needed for the displacements fields projection on Williams' model can be deduced with a reliable estimate of Irwin's plastic radius

Effect of Fe and Mn Content on the Microstructures and Tensile Behaviour of AlSi7Cu3 Alloy: Thermal Analysis and Tensile Tests

The present study was performed on two AlSi7Cu3 alloys with different Fe and Mn contents (standard alloy and high-Fe/Mn alloy). The evolution of microstructures during solidification of the standard AlSi7Cu3 alloy was investigated by thermal analysis and interrupted quenching test. The effect of Fe and Mn content on the solidification reaction and sequence were studied. The results show that increasing the Fe and Mn content changes the precipitation sequence of the iron-intermetallic α-Al15 (Fe,Mn)3Si2 and β-Al5FeSi, leading to the precipitation of α + β phases at a higher temperature. Microstructural characterizations were also performed on the fully solidified alloys to study the effect of Fe and Mn content on the microstructure of AlSi7Cu3 alloy. Fe and Mn were found to promote the formation of Fe-intermetallics. With the increase of Fe/Mn content, Fe-intermetallics increased in both size and amount, while more small pores (Feret diameter < 200 µm) were also introduced. 3D networks of α-Al15(Fe,Mn)3Si2 and β-Al5FeSi phases were revealed by Lab X-ray Computed Tomography, however, it is difficult to perform a quantitative analysis of the respective volume fraction of α-Al15(Fe,Mn)3Si2 and β-Al5FeSi phase from their 3D morphology. Monotonic tensile tests on both alloys show the mechanical properties of the studied alloys were not sensitive to the Fe/Mn content, while the fractography analysis reveals that cracks growth and final fracture under monotonic load are more prone to occur through the eutectic Si, Al2Cu phases and iron-intermetallics than through aluminium matrix.The authors wish to thank the ANR (Agence Nationale de la Recherche) MatetPro project INDiANA (ANR-12RMNP-0011) for funding the study on Al-Si alloys, Pierre Osmond from PSA Peugeot Citroën for providing the material of this study and the China Scholarship Council (CSC) for funding the PhD thesis of Zaidao Li. The ISIS4D X-Ray CT platform which has been funded by International Campus on Safety and Intermodality in Transportation (CISIT), the Nord-Pas-de-Calais Region, the European Community and the National Center for Scientific Research is also acknowledged for microtomographic acquisition, and thank the Common Center of Microscopy (CCM) of Lille University for the SEM and EDS. The authors also thank Dr. Dan Luo for her assistance with casting and SEM analysis. UK Research & Innovation (UKRI) [Engineering & Physical Sciences Research Council (EPSRC) EP/N007638/1]

Amorçage et propagation de fissures de fatigue dans un alliage Al-Si A319 lors d'essais in situ de fatigue oligocyclique sous tomographie synchrotron

Dans l'industrie automobile, le procédé généralement utilisé pour la fabrication des culasses est le moulage en coquille par gravité. Il est progressivement remplacé par le Procédé à Modèle Perdu (PMP) dans un but d'optimisation de la géométrie, de réduction des coûts et de contrôle de la consommation des véhicules. Cependant, les pièces automobiles en alliage d'aluminium fabriquées par PMP ont une microstructure plus grossière et plus de pores que les pièces fabriquées en moulage en coquille par gravité à des vitesses de refroidissement plus grandes. Cette microstructure a une influence majeure sur le comportement en fatigue et les mécanismes d'endommagement des alliages Al-Si. Dans ces travaux, les mécanismes d'endommagement en fatigue oligocyclique ont été étudiés lors d'essais in situ sous tomographie de synchrotron (SLS et ESRF) à la fois à température ambiante et à la température de service des culasses (250°C°) sur des échantillons prélevés dans les zones les plus critiques de la culasse (face flamme). Préalablement, des observations sous microtomographe par rayons X de laboratoire (MATEIS et ISIS4D) ont permis de sélectionner les échantillons et les zones d'observations et d'analyses au regard de la taille et de la localisation des pores en particulier. La reconstruction 3D des images permet de visualiser les différents éléments de la microstructure (Si eutectique, intermétalliques au fer (?(AlFeMnSi) et ? (AlFeSi)), intermétalliques au cuivre (Al2Cu et AlCuMgSi) à haute résolution (1,6 - 2.5 µm de taille de voxel). Le lien entre la microstructure et l'amorçage et la propagation des microfissures a ainsi pu être étudié en volume. Cette microstructure sert par ailleurs de texture naturelle pour la corrélation d'images volumiques. Grace aux champs de déplacement 3D mesurés, la localisation et le développement de la déformation sont suivis au cours du cyclage. Il est démontré que la microstructure complexe 3D du matériau et la présence des pores produit des hétérogénéités locales qui peuvent être corrélées avec l'amorçage et la propagation des fissures de fatigue

X-ray tomography studies on porosity and particle size distribution in cast in-situ Al-Cu-TiB2 semi-solid forged composites

X-ray computed tomography (XCT) was used to characterise the internal microstructure and clustering behaviour of TiB2 particles in in-situ processed Al-Cu metal matrix composites prepared by casting method. Forging was used in semi-solid state to reduce the porosity and to uniformly disperse TiB2 particles in the composite. Quantification of porosity and clustering of TiB2 particles was evaluated for different forging reductions (30% and 50% reductions) and compared with an as- cast sample using XCT. Results show that the porosity content was decreased by about 40% due to semi-solid forging as compared to the as-cast condition. Further, XCT results show that the 30% forging reduction resulted in greater uniformity in distribution of TiB2 particles within the composite compared to as-cast and the 50% forge reduction in semi-solid state. These results show that the application of forging in semi-solid state enhances particle distribution and reduces porosity formation in cast in-situ Al-Cu-TiB2 metal matrix composites

On the use of flat-fields for tomographic reconstruction

Seeking for quantitative tomographic images, it is of utmost importance to limit reconstruction artifacts. Detector imperfections, inhomogeneity of the incident beam, as classically observed in synchrotron beamlines, and their variations in time are a major cause of reconstruction bias such as " ring artifacts ". The present study aims at proposing a faithful estimate of the incident beam local intensity for each acquired projection during a scan, without revisiting the process of data acquisition itself. Actual flat-fields (acquired without specimen in the beam) and sinogram borders (when the specimen is present), which are not masked during the scan, are exploited to construct a suited instantaneous detector-wide flat-field. The proposed treatment is fast and simple. Its performance is assessed on a real scan acquired at ESRF ID19 beamline. Different criteria are used including residuals, i.e., difference between projections of reconstruction and actual projections. All confirm the benefit of the proposed procedure