Search results for: Crack welding

Authors: Kuen-Ming Shu, Cheng-Yu Chen

Abstract:

A vibrating-fork sensor can measure the level height of solids and liquids and operates according to the principle that vibrations created by piezoelectric ceramics are transmitted to the vibrating fork, which produces resonance. When the vibrating fork touches an object, its resonance frequency changes and produces a signal that returns to a controller for immediate adjustment, so as to effectively monitor raw material loading. The design of the vibrating fork in a vibrating-fork material sensor is crucial. In this paper, ANSYS finite element analysis software is used to perform modal analysis on the vibrations of the vibrating fork. In addition, to design and produce a superior vibrating fork, the dimensions and welding shape of the vibrating fork are compared in a simulation performed using the Taguchi method.

Keywords: Vibrating fork, piezoelectric ceramics, sound wave, ANSYS, Taguchi method, modal analysis.

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Authors: Esther T. Akinlabi, Stephen A. Akinlabi

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This paper reports the tensile fracture location characterizations of dissimilar friction stir welds between 5754 aluminium alloy and C11000 copper. The welds were produced using three shoulder diameter tools; namely, 15, 18 and 25 mm by varying the process parameters. The rotational speeds considered were 600, 950 and 1200 rpm while the feed rates employed were 50, 150 and 300 mm/min to represent the low, medium and high settings respectively. The tensile fracture locations were evaluated using the optical microscope to identify the fracture locations and were characterized. It was observed that 70% of the tensile samples failed in the Thermo Mechanically Affected Zone (TMAZ) of copper at the weld joints. Further evaluation of the fracture surfaces of the pulled tensile samples revealed that welds with low Ultimate Tensile Strength either have defects or intermetallics present at their joint interfaces.

Keywords: fracture location, friction stir welding, intermetallics, metallography,

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Authors: Esmaeil Asadzadeh, Mehtab Alam

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Progressive collapse of the layered hyperbolic tower shells are studied considering the influences of changes in the supporting columns’ types and angles. 3-D time history analyses employing the finite element method are performed for the towers supported with I-type and ᴧ-type column. It is found that the inclination angle of the supporting columns is a very important parameter in optimization and safe design of the cooling towers against the progressive collapse. It is also concluded that use of Demand Capacity Ratio (DCR) criteria of the linear elastic approach recommended by GSA is un-conservative for the hyperbolic tower shells.

Keywords: Progressive collapse, cooling towers, finite element analysis, crack generation, reinforced concrete.

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Authors: Thomas Jin-Chee Liu

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Using the finite element analyses, this paper discusses the effects of temperature-dependent material properties on the stress and temperature fields in a cracked metal plate under the electric current load. The practical and complicated results are obtained when the temperature-dependent material properties are adopted in the analysis. If the simplified (temperature-independent) material properties are used, incorrect results will be obtained.

Keywords: Joule heating, temperature-dependent, crack tip, finite element.

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Authors: Bahareh Gholamzadeh, Hooman Nabovati

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Fiber optic sensor technology offers the possibility of sensing different parameters like strain, temperature, pressure in harsh environment and remote locations. these kinds of sensors modulates some features of the light wave in an optical fiber such an intensity and phase or use optical fiber as a medium for transmitting the measurement information. The advantages of fiber optic sensors in contrast to conventional electrical ones make them popular in different applications and now a day they consider as a key component in improving industrial processes, quality control systems, medical diagnostics, and preventing and controlling general process abnormalities. This paper is an introduction to fiber optic sensor technology and some of the applications that make this branch of optic technology, which is still in its early infancy, an interesting field.

Keywords: Fiber optic sensors, distributed sensors, sensorapplication, crack sensor.

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Authors: A.Urbach, M. Banov, V. Turko, Y.Feshchuk

Abstract:

the work contains the results of complex investigation related to the evaluation of condition of working blades of gas turbine engines during fatigue tests by applying the acoustic emission method. It demonstrates the possibility of estimating the fatigue damage of blades in the process of factory tests. The acoustic emission criteria for detecting and testing the kinetics of fatigue crack distribution were detected. It also shows the high effectiveness of the method for non-destructive testing of condition of solid and cooled working blades for high-temperature gas turbine engines.

Keywords: acoustic emission, blades for gas turbine engines, fatigue damage, diagnostics

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Authors: A. El Amri, M. El Yakhloufi Haddou, A. Khamlichi

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The numerical simulation based on the Finite Element Method (FEM) is widely used in academic institutes and in the industry. It is a useful tool to predict many phenomena present in the classical manufacturing forming processes such as fracture. But, the results of such numerical model depend strongly on the parameters of the constitutive behavior model. The influences of thermal and mechanical loads cause damage. The temperature and strain rate dependent materials’ properties and their modelling are discussed. A Johnson-Cook Model of damage has been selected for the numerical simulations. Virtual software called the ABAQUS 6.11 is used for finite element analysis. This model was introduced in order to give information concerning crack initiation during thermal and mechanical loads.

Keywords: Thermomechanical fatigue, failure, numerical simulation, fracture, damages.

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Authors: Alireza BozorgianÏî Navid Majdi Nasab, Hassan Mirzazadeh

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In this paper, the effect of modified clay on the mechanical efficiency of epoxy resin is examined. Studies by X ray diffraction and microscopic transient electron method show that modified clay distribution in polymer area is intercalated kind. Examination the results of mechanical tests shows that existence of modified clay in epoxy area increases pressure yield strength, tension module and nano composite fracture toughness in relate of pure epoxy. By microscopic examinations it is recognized too that the action of toughness growth of this kind of nano composite is due to crack deflection, formation of new surfaces and fracture of clay piles.

Keywords: Nano clay, Epoxy, Toughness, Composite

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Authors: S. I. Durowaye, O. P. Gbenebor, B. O. Bolasodun, I. O. Rufai, V. O. Durowaye

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Particles are the most common and cheapest reinforcement producing discontinuous reinforced composites with isotropic properties. Conventional fabrication methods can be used to produce a wide range of product forms, making them relatively inexpensive. Optimising composite development must include consideration of all the fundamental aspect of particles including their size, shape, volume fraction, distribution and mechanical properties. Research has shown that the challenges of low fracture toughness, poor crack growth resistance and low thermal stability can be overcome by reinforcement with particles. The unique properties exhibited by micro particles reinforced ceramic composites have made them to be highly attractive in a vast array of applications.

Keywords: Ceramic composites, Mechanical properties, Microparticles, Thermal stability.

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Authors: Amir Ansari, Ehsan Shahrjerdi, Ehsan Amini

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To investigate the behavior of sheet metals during forming tailor welded blanks (TWB) of various thickness made via Co2 Laser welding are under consideration. These blanks are formed used two different forming methods of rubber as well as the conventional punch and die methods. The main research objective is the effects of using a rubber die instead of a solid one the displacement of the weld line and the press force needed for forming. Specimens with thicknesses of 0.5, 0.6, 0.8 and 1mm are subjected to Erichsen two dimensional tests and the resulted force for each case are compared. This is followed by a theoretical and numerical study of press force and weld line displacement. It is concluded that using rubber pad forming (RPF) causes a reduction in weld line displacement and an increase in the press force.

Keywords: Rubber pad forming, Tailor welded blank, Thickness ratio, Weld line displacement.

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Authors: FiroozBakhtiari-Nejad, Hamidreza Rostami, MeysamMirzaee, Mona Zandbaf

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Dynamic tests are an important step of the design of engineering structures, because the accuracy of predictions of theoretical–numerical procedures can be assessed. In experimental test of moving loads that is one of the major research topics, the load is modeled as a simple moving mass or a small vehicle. This paper deals with the applicability of Non-contact Moving Load (NML) for vibration analysis. For this purpose, an experimental set-up is designed to generate the different types of NML including constant and harmonic. The proposed method relies on pressurized air which is useful, especially when dealing with fragile or sensitive structures. To demonstrate the performance of this system, the set-up is employedfor a modal analysis of a beam and detecting crack of the beam.The obtained results indicate that the experimental set-up for NML can be an attractive alternative to the moving load problems.

Keywords: Experimental analysis, Moving load, Non-contact excitation.

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Authors: M. S. Kaiser

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An attempt has been made to determine the strength and impact properties of Cr-Mo steel weld and base materials by varying the current during manual metal arc welding. Toughness over a temperature range from -32 to 100°C of base, heat affected zone (HAZ) and weld zones at three current settings are made. It is observed that the deterioration in notch toughness at any zone with the temperature decreases. The values of notch toughness for all zones at -32°C are almost same for any current settings. The values of notch toughness at HAZ area are higher than that of weld area due to the coarsening of ferrite grain of HAZ occurs with higher heat input. From microhardness and microstructure result, it can be concluded that large inclusion content in weld deposit is the cause of lower notch toughness value.

Keywords: Chromium-Molybdenum steel, post-weld heat treatment, heat affected zone, microstructure.

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Authors: Dalvir Singh, Somnath Chattopadhyaya

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During welding or flame cutting of metals, the prediction of heat affected zone (HAZ) is critical. There is need to develop a simple mathematical model to calculate the temperature variation in HAZ and derivative analysis can be used for this purpose. This study presents analytical solution for heat transfer through conduction in mild steel plate. The homogeneous and nonhomogeneous boundary conditions are single variables. The full field analytical solutions of temperature measurement, subjected to local heating source, are derived first by method of separation of variables followed with the experimental visualization using infrared imaging. Based on the present work, it is suggested that appropriate heat input characteristics controls the temperature distribution in and around HAZ.

Keywords: Conduction Heat Transfer, Heat Affected Zone (HAZ), Infra-Red Imaging, Numerical Method, Orthogonal Function, Plasma Arc Cutting, Separation of Variables, Temperature Measurement.

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Authors: Gurmeet Singh Cheema, Navjotinder Singh, Gurjinder Singh, Amardeep Singh Kang

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Aluminium and its alloys have excellent corrosion resistant properties, ease of fabrication and high specific strength to weight ratio. In this investigation an attempt has been made to study the effect of different post weld heat treatment methods on the mechanical and metallurgical properties of TIG welded joints of the commercial aluminium alloy. Three different methods of post weld heat treatments are solution heat treatment, artificial ageing and combination of solution heat treatment and artificial aging are given to TIG welded aluminium joints. Mechanical and metallurgical properties of As welded joints of the aluminium alloys and post weld heat treated joints of the aluminium alloys were examined.

Keywords: Aluminium Alloys, Post weld Heat Treatment, TIG welding.

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Authors: Essam A. Al-Bahkali

Abstract:

A three-dimensional finite element modeling for austenitic stainless steel AISI 304 annealed condition sheets of 1.0 mm thickness are developed using ABAQUS® software. This includes spot welded and weld bonded joints models. Both models undergo thermal heat caused by spot welding process and then are subjected to axial load up to the failure point. The properties of elastic and plastic regions, modulus of elasticity, fracture limit, nugget and heat affected zones are determined. Complete loaddisplacement curve for each joining model is obtained and compared with the experiment data and with the finite element models without including the effect of thermal process. In general, the results obtained for both spot welded and weld-bonded joints affected by thermal process showed an excellent agreement with the experimental data.

Keywords: Heat Affected Zone, Spot Welded, Thermal Process, Weld-Bonded.

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Authors: Elena B. Cherepetskaya, Vladimir A. Makarov, Dmitry V. Morozov, Ivan E. Sas

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Laboratory studies of the stress-strain behavior of rocks specimens were conducted by using acoustic emission and laser-ultrasonic diagnostics. The sensitivity of the techniques allowed changes in the internal structure of the specimens under uniaxial compressive load to be examined at micro- and macro scales. It was shown that microcracks appear in geologic materials when the stress level reaches about 50% of breaking strength. Also, the characteristic stress of the main crack formation was registered in the process of single-stage compression of rocks. On the base of laser-ultrasonic echoscopy, 2D visualization of the internal structure of rocky soil specimens was realized, and the microcracks arising during uniaxial compression were registered.

Keywords: Acoustic emission, geomaterial, laser ultrasound, uniaxial compression.

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Authors: Emilio A. Berny-Brandt, Sonia E. Ruiz

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Steel tubular towers serving as support structures for large wind turbines are subjected to several hundred million stress cycles caused by the turbulent nature of the wind. This causes highcycle fatigue, which could govern the design of the tower. Maintaining the support structure after the wind turbines reach its typical 20-year design life has become a common practice; however, quantifying the changes in the reliability on the tower is not usual. In this paper the effect of fatigue damage in the wind turbine structure is studied whit the use of fracture mechanics, and a method to estimate the reliability over time of the structure is proposed. A representative wind turbine located in Oaxaca, Mexico is then studied. It is found that the system reliability is significantly affected by the accumulation of fatigue damage. 

Keywords: Crack growth, fatigue, Monte Carlo simulation, structural reliability, wind turbines

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Authors: W. Wu, S. Utili

Abstract:

Based on the kinematic approach of limit analysis, a full set of upper bound solutions for the stability of homogeneous rock slopes subjected to tension cracks are obtained. The generalized Hoek-Brown failure criterion is employed to describe the non-linear strength envelope of rocks. In this paper, critical failure mechanisms are determined for cracks of known depth but unspecified location, cracks of known location but unknown depth, and cracks of unspecified location and depth. It is shown that there is a nearly up to 50% drop in terms of the stability factors for the rock slopes intersected by a tension crack compared with intact ones. Tables and charts of solutions in dimensionless forms are presented for ease of use by practitioners.

Keywords: Hoek-Brown failure criterion, limit analysis, rock slope, tension cracks.

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Authors: Kuen-Ming Shu, Jyun-Wei Chen

Abstract:

Encapsulated O-rings are specifically designed to address the problem of sealing the most hostile chemicals and extreme temperature applications. Ultrasonic vibration hot embossing and ultrasonic welding techniques provide a fast and reliable method to fabricate encapsulated O-ring. This paper performs the design and analysis method of the acoustic horns with double extrusion to process tube double side flange simultaneously. The paper deals with study through Finite Element Method (FEM) of ultrasonic stepped horn used to process a capsulated O-ring, the theoretical dimensions of horns, and their natural frequencies and amplitudes are obtained through the simulations of COMOSOL software. Furthermore, real horns were fabricated, tested and verified to proof the practical utility of these horns. 

Keywords: Encapsulated O-rings, ultrasonic vibration hot embossing, flange making, acoustic horn, finite element analysis.

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Authors: Z. Heirany, M. Ghaemian

Abstract:

Behavior of dams against the seismic loads has been studied by many researchers. Most of them proposed new numerical methods to investigate the dam safety. In this paper, to study the effect of nonlinear parameters of concrete in gravity dams, a twodimensional approach was used including the finite element method, staggered method and smeared crack approach. Effective parameters in the models are physical properties of concrete such as modulus of elasticity, tensile strength and specific fracture energy. Two different models were used in foundation (mass-less and massed) in order to determine the seismic response of concrete gravity dams. Results show that when the nonlinear analysis includes the dam- foundation interaction, the foundation-s mass, flexibility and radiation damping are important in gravity dam-s response.

Keywords: Numerical methods; concrete gravity dams; finiteelement method; boundary condition

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Authors: O. Hassoon, M. Tarfoui, A. El Malk

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Fiber Bragg optic sensor is embedded in composite material to detect and monitor the damage that occurs in composite structures. In this paper, we deal with the mode-Ι delamination to determine the material strength to crack propagation, using the coupling mode theory and T-matrix method to simulate the FBGs spectrum for both uniform and non-uniform strain distribution. The double cantilever beam test is modeled in FEM to determine the longitudinal strain. Two models are implemented, the first is the global half model, and the second is the sub-model to represent the FBGs with higher refined mesh. This method can simulate damage in composite structures and converting strain to a wavelength shifting in the FBG spectrum.

Keywords: Fiber Bragg grating, Delamination detection, DCB, FBG spectrum, Structure health monitoring.

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Authors: Hossein Mamusi, Abolfazl Masoumi, Ramezanali Mahdavinezhad

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Tailor-welded Blanks (TWBs) are tailor made for different complex component designs by welding multiple metal sheets with different thicknesses, shapes, coatings or strengths prior to forming. In this study the Hemispherical Die Stretching (HDS) test (out-of-plane stretching) of TWBs were simulated via ABAQUS/Explicit to obtain the Forming Limit Diagrams (FLDs) of Stainless steel (AISI 304) laser welded blanks with different thicknesses. Two criteria were used to detect the start of necking to determine the FLD for TWBs and parent sheet metals. These two criteria are the second derivatives of the major and thickness strains that are given from the strain history of simulation. In the other word, in these criteria necking starts when the second derivative of thickness or major strain reaches its maximum. With having the time of onset necking, one can measure the major and minor strains at the critical area and determine the forming limit curve.

Keywords: TWB, Forming Limit Diagram, Necking criteria, ABAQUS/Explicit

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Authors: N. Mahmoudi

Abstract:

Composite materials have important assets compared to traditional materials. They bring many functional advantages: lightness, mechanical resistance and chemical, etc. In the present study we examine the effect of a circular central notch and a precrack on the tensile fracture of two woven composite materials. The tensile tests were applied to a standardized specimen, notched and a precarcked (orientation of the crack 0°, 45° and 90°). These tensile tests were elaborated according to an experimental planning design of the type 23.31 requiring 24 experiments with three repetitions. By the analysis of regression, we obtained a mathematical model describing the maximum load according to the influential parameters (hole diameter, precrack length, angle of a precrack orientation). The specimens precracked at 90° have a better behavior than those having a precrack at 45° and still better than those having of the precracks oriented at 0°. In addition the maximum load is inversely proportional to the notch size.

Keywords: Polymer matrix, Glasses, Fracture.

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Authors: Lydia Chan, Islam Shyha, Dale Dreyer, John Hamilton, Phil Hackney

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Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.

Keywords: Cylindrical turning, nickel superalloy, turning of overlay, weld overlay.

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Authors: S.C. Chin, N. Shafiq, M.F. Nuruddin

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In the modern construction practices, industrial wastes or by-products are largely used as raw materials in cement and concrete. These impart many benefits to the environment and bringabout an economic impact because the cost of waste disposal is constantly increasing due to strict environmental regulations. It was reported in literature that the leakage of oil onto concrete element in older cement grinding unit resulted in concrete with greater resistance to freezing and thawing. This effect was thought to be similar to adding an air-entraining chemical admixture to concrete. This paper presents an investigation on the load deflection behaviour and crack patterns of reinforced concrete (RC) beams subjected to four point loading. Ten 120x260x1900 mm beams were cast with 100% ordinary Portland cement (OPC) concrete, 20% fly ash (FA) and 20% rice husk ash (RHA) blended cement concrete. 0.15% dosage of admixtures (used engine oil, new engine oil, and superplasticizer) was used throughout the experiment. Results show that OPC and OPC/RHA RC beams containing used engine oil and superplasticizer exhibit higher capacity, 18-26% than their corresponding control mix.

Keywords: by-products, RC beams, superplasticizer, used engine oil

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Authors: Jackeline Kafie-Martinez, Peter B. Keating

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A three-dimensional finite element model is developed to capture the stress field generated in connected plates during the installation of hot-driven rivets. Clamping stress is generated when a steel rivet heated to approximately 1000 °C comes in contact with the material to be fastened at ambient temperature. As the rivet cools, thermal contraction subjects the rivet into tensile stress, while the material being fastened is subjected to compressive stress. Model characteristics and assumptions, as well as steel properties variation with respect to temperature are discussed. The thermal stresses developed around the rivet hole are assessed and reported. Results from the analysis are utilized to detect possible regions for fatigue crack propagation under cyclic loads.

Keywords: Jackeline Kafie-Martinez, Peter B. Keating.

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Authors: Khoa Tan Nguyen, Tuan Anh Le, Kihak Lee

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This paper presents the flexural response of Reinforced Geopolymer Concrete (RGPC) beams. A commercial finite element (FE) software ABAQUS has been used to perform a structural behavior of RGPC beams. Using parameters such: stress, strain, Young’s modulus, and Poisson’s ratio obtained from experimental results, a beam model has been simulated in ABAQUS. The results from experimental tests and ABAQUS simulation were compared. Due to friction forces at the supports and loading rollers; slip occurring, the actual deflection of RGPC beam from experimental test results were slightly different from the results of ABAQUS. And there is good agreement between the crack patterns of fly ash-based geopolymer concrete generated by FE analysis using ABAQUS, and those in experimental data.

Keywords: Geopolymer concrete beam, finite element method, stress strain relation, modulus elasticity.

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Authors: Amir M. Alani, Morteza Aboutalebi

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This paper in essence presents comparative experimental data on the mechanical performance of steel and synthetic fibre-reinforced concrete under compression, tensile split and flexure. URW1050 steel fibre and HPP45 synthetic fibre, both with the same concrete design mix, have been used to make cube specimens for a compression test, cylinders for a tensile split test and beam specimens for a flexural test. The experimental data demonstrated steel fibre reinforced concrete to be stronger in flexure at early stages, whilst both fibre reinforced concrete types displayed comparatively the same performance in compression, tensile splitting and 28-day flexural strength. In terms of post-crack controlHPP45 was preferable.

Keywords: Steel Fibre, Synthetic Fibre, Fibre Reinforced Concrete, Failure, Ductility, Experimental Study.

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Authors: B. Singh, B. K. Nanda

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The characterization and modeling of the dynamic behavior of many built-up structures under vibration conditions is still a subject of current research. The present study emphasizes the theoretical investigation of slip damping in layered and jointed welded cantilever structures using finite element approach. Application of finite element method in damping analysis is relatively recent, as such, some problems particularly slip damping analysis has not received enough attention. To validate the finite element model developed, experiments have been conducted on a number of mild steel specimens under different initial conditions of vibration. Finite element model developed affirms that the damping capacity of such structures is influenced by a number of vital parameters such as; pressure distribution, kinematic coefficient of friction and micro-slip at the interfaces, amplitude, frequency of vibration, length and thickness of the specimen. Finite element model developed can be utilized effectively in the design of machine tools, automobiles, aerodynamic and space structures, frames and machine members for enhancing their damping capacity.

Keywords: Amplitude, finite element method, slip damping, tack welding.

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Authors: Andras Szekrenyes

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This work presents the mixed-mode II/III prestressed split-cantilever beam specimen for the fracture testing of composite materials. In accordance with the concept of prestressed composite beams one of the two fracture modes is provided by the prestressed state of the specimen, and the other one is increased up to fracture initiation by using a testing machine. The novel beam-like specimen is able to provide any combination of the mode-II and mode-III energy release rates. A simple closed-form solution is developed using beam theory as a data reduction scheme and for the calculation of the energy release rates in the new configuration. The applicability and the limitations of the novel fracture mechanical test are demonstrated using unidirectional glass/polyester composite specimens. If only crack propagation onset is involved then the mixed-mode beam specimen can be used to obtain the fracture criterion of transparent composite materials in the GII - GIII plane in a relatively simple way.

Keywords: Composite, fracture mechanics, toughness testing, mixed-mode II/III fracture.

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