Commenced in January 2007
Paper Count: 30011
Assessment of Ultra-High Cycle Fatigue Behavior of EN-GJL-250 Cast Iron Using Ultrasonic Fatigue Testing Machine
Abstract:High cycle fatigue comprising up to 107 load cycles has been the subject of many studies, and the behavior of many materials was recorded adequately in this regime. However, many applications involve larger numbers of load cycles during the lifetime of machine components. In this ultra-high cycle regime, other failure mechanisms play, and the concept of a fatigue endurance limit (assumed for materials such as steel) is often an oversimplification of reality. When machine component design demands a high geometrical complexity, cast iron grades become interesting candidate materials. Grey cast iron is known for its low cost, high compressive strength, and good damping properties. However, the ultra-high cycle fatigue behavior of cast iron is poorly documented. The current work focuses on the ultra-high cycle fatigue behavior of EN-GJL-250 (GG25) grey cast iron by developing an ultrasonic (20 kHz) fatigue testing system. Moreover, the testing machine is instrumented to measure the temperature and the displacement of the specimen, and to control the temperature. The high resonance frequency allowed to assess the behavior of the cast iron of interest within a matter of days for ultra-high numbers of cycles, and repeat the tests to quantify the natural scatter in fatigue resistance.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.3455657Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
 C. BATHIAS and P. C. Paris, Gigacycle fatigue in mechanical practice vol. 185: CRC Press, 2004, pp. 19-119.
 "Eurocode 3- Design of steel structures - Part 1-9_ EN 1993-1-9," ed, 2005.
 " Eurocode 9. Design of aluminium structures. Structures susceptible to fatigue, Part2," ed, 1999-2:2000.
 C. Bathias, "There is no infinite fatigue life in metallic materials," Fatigue and fracture of engineering materials and structures, vol. 22, pp. 559-566, 1999.
 C. Sonsino, "Course of SN-curves especially in the high-cycle fatigue regime with regard to component design and safety," International Journal of Fatigue, vol. 29, pp. 2246-2258, 2007.
 H. Mughrabi, "On ‘multi‐stage’fatigue life diagrams and the relevant life‐controlling mechanisms in ultrahigh‐cycle fatigue," Fatigue & Fracture of Engineering Materials & Structures, vol. 25, pp. 755-764, 2002.
 C. Wang, D. Wagner, Q. Wang, and C. Bathias, "Gigacycle fatigue initiation mechanism in Armco iron," International Journal of Fatigue, vol. 45, pp. 91-97, 2012.
 C. Wang, J. Petit, Z. Huang, and D. Wagner, "Investigation of crack initiation mechanisms responsible for the fish eye formation in the Very High Cycle Fatigue regime," International Journal of Fatigue, vol. 119, pp. 320-329, 2019.
 Y. Hong and C. Sun, "The nature and the mechanism of crack initiation and early growth for very-high-cycle fatigue of metallic materials–An overview," Theoretical and Applied Fracture Mechanics, vol. 92, pp. 331-350, 2017.
 C. Bathias, "Influence of the metallurgical instability on the gigacycle fatigue regime," International Journal of Fatigue, vol. 32, pp. 535-540, 2010.
 W. P. Mason, "Piezoelectronic Crystal and Their Application in Ultrasonics," Van Nostrand, p. 161, 1950.
 Y. Lage, M. Freitas, L. Reis, A. Ribeiro, and D. Montalvão, "Instumentation of Ultrasonic High-Frequency Machine to Estimate Applied Stress in Middle Section of Specimen," in Procs of 15th International Conference on Experimental Mechanics, 2012.
 Y. Lage, A. Ribeiro, D. Montalvão, L. Reis, and M. Freitas, "Automation in strain and temperature control on VHCF with an ultrasonic testing facility," in Application of Automation Technology in Fatigue and Fracture Testing and Analysis, ed: ASTM International, 2014.
 H. Mayer, "Ultrasonic torsion and tension–compression fatigue testing: Measuring principles and investigations on 2024-T351 aluminium alloy," International Journal of Fatigue, vol. 28, pp. 1446-1455, 2006.
 C. Bathias, "Piezoelectric fatigue testing machines and devices," International Journal of Fatigue, vol. 28, pp. 1438-1445, 2006.
 V. Anes, D. Montalvao, A. Ribeiro, M. Freitas, and M. Fonte, "Design and instrumentation of an ultrasonic fatigue testing machine," 2011.
 D. Wagner, F. J. Cavalieri, C. Bathias, and N. Ranc, "Ultrasonic fatigue tests at high temperature on an austenitic steel," Propulsion and Power Research, vol. 1, pp. 29-35, 2012.
 L. Xu, Q. Wang, and M. Zhou, "Micro-crack initiation and propagation in a high strength aluminum alloy during very high cycle fatigue," Materials Science and Engineering: A, vol. 715, pp. 404-413, 2018.
 S. Stanzl-Tschegg and H. Mayer, "Fatigue and fatigue crack growth of aluminium alloys at very high numbers of cycles," International Journal of Fatigue, vol. 23, pp. 231-237, 2001.
 Y. Lage, M. Freitas, D. Montalvao, A. Ribeiro, and L. Reis, "Ultrasonic fatigue analysis on steel specimen with temperature control: evaluation of variable temperature effect," 2012.
 A. Gulyaev, "Physical Metallurgy
[in Russian], Metallurgiya, Moscow (1977)," Google Scholar, p. 647.
 T. Willidal, W. Bauer, and P. Schumacher, "Stress/strain behaviour and fatigue limit of grey cast iron," Materials Science and Engineering: A, vol. 413, pp. 578-582, 2005.
 C. Bathias and A. Pineau, Fatigue of materials and structures: Wiley Online Library, 2010.
 F. Cavalieri, C. Bathias, N. Ranc, A. Cardona, and J. Risso, "Ultrasonic fatigue analysis on an austenitic steel at high temperature," Mecánica Computacional, vol. 27, pp. 1205-1224, 2008.
 L. Trško, F. Nový, O. Bokůvka, and M. Jambor, "Ultrasonic Fatigue Testing in the Tension-Compression Mode," Journal of visualized experiments: JoVE, 2018.
 I. Marines, G. Dominguez, G. Baudry, J.-F. Vittori, S. Rathery, J.-P. Doucet, et al., "Ultrasonic fatigue tests on bearing steel AISI-SAE 52100 at frequency of 20 and 30 kHz," International Journal of Fatigue, vol. 25, pp. 1037-1046, 2003.
 N. Schneider, J. Bödecker, C. Berger, and M. Oechsner, "Frequency effect and influence of testing technique on the fatigue behaviour of quenched and tempered steel and aluminium alloy," International Journal of Fatigue, vol. 93, pp. 224-231, 2016.
 H. Germann, P. Starke, and D. Eifler, "Resistivity-based evaluation of the fatigue behavior of cast irons," Metallurgical and Materials Transactions A, vol. 43, pp. 2792-2798, 2012.
 T. Rausch, P. Beiss, C. Broeckmann, S. Lindlohr, and R. Weber, "Application of quantitave image analysis of graphite structures for the fatigue strength estimation of cast iron materials," Procedia Engineering, vol. 2, pp. 1283-1290, 2010.