TY - CONF A1 - Zhu, Jiangchao T1 - Burst behaviours of aero-engine turbine disk at overspeed conditions N2 - This presentation focuses on the basic ideas and current status of the development of an arithmetical method to predict the failure rotational speed of turbine disks. The certification specification requires that a gas turbine aero-engine must hold 5 minutes at overspeed conditions without critical failure. Therefore, instead of experimental proof from spin-tests using test-disks similar to engine components, it is considered to use simple specimen with similar test conditions compared to real overspeed scenarios. These test conditions, or stress fields are determined using arithmetical method, e.g. finite element method, with consideration of fracture mechanics under quasi-static conditions with a given rotational speed. Failure modes like hoop burst and rim peeling are considered during determination of stress fields. Various crack-tip parameters are used to explore the similarity of stress field between simple specimen and real overspeed scenarios. Additionally, probabilistic aspects and the implementation of a global stability criterion for overspeed analysis are also considered. T2 - 43rd Materials Mechanics Seminar CY - Sani, Chalkidiki, Greece DA - 06.06.2022 KW - Structural integrity KW - Fracture mechanics KW - Turbine disk KW - Overspeed PY - 2022 AN - OPUS4-55081 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zhu, Jiangchao T1 - Fracture mechanics-based structural integrity assessment of aero-engine turbine disks under overspeed conditions N2 - Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The actual part qualification and certification procedures make use of spin-tests conducted on production-similar disks. While these tests provide, on the one hand, a reliable definition of the critical conditions for real components, on the other hand they represent a relevant cost item for engine manufacturers. The aim of this work is to present part of a fracture mechanics-based procedure under development which aims at replacing the tests on production-similar disks with lab tests on fracture mechanics specimens. In particular, the rim-peeling failure mode is considered as case study. A semi-circular surface crack is modelled at the most stressed region at the diaphragm of a turbine disk, with the crack plane perpendicular to the radial direction. The crack is therefore subjected to a biaxial stress state and grows under increasing rotational speed until it triggers the rim-peeling failure. The finite element simulation of the cracked disk considers the real thermal and mechanical loading conditions. In order to design a lab representative specimen, beside the crack driving force, expressed in terms of J-integral, also the constraint to plastic deformation e.g., stress triaxiality, at the crack-tip must be similar for the same crack in the specimen and in the disk. This has been achieved and as expected, both the highest J-integral and constraint factor are calculated at the same location along the crack front for both disk and specimen. The results of the structural integrity assessment in the form of a Failure Assessment Diagram (FAD) show good agreement between designed specimen and disk both in terms of expected failure mode and value of the critical speed. Probabilistic aspects are also considered in the calculations. T2 - Turbo Expo 2022 CY - Rotterdam, Netherlands DA - 13.06.2022 KW - Structural integrity KW - Fracture mechanics KW - Turbine disk KW - Overspeed PY - 2022 AN - OPUS4-55082 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Griesche, Axel A1 - Pfretzschner, Beate A1 - Taparli, Ugur Alp A1 - Kardjilov, N. T1 - Time-Resolved Neutron Bragg-Edge Imaging: A Case Study by Observing Martensitic Phase Formation in Low Temperature Transformation (LTT) Steel during GTAW N2 - Polychromatic and wavelength-selective neutron transmission radiography were applied during bead-on-plate welding on 5 mm thick sheets on the face side of martensitic low transformation temperature (LTT) steel plates using gas tungsten arc welding (GTAW). The in situ visualization of austenitization upon welding and subsequent α’-martensite formation during cooling could be achieved with a temporal resolution of 2 s for monochromatic imaging using a single neutron wavelength and of 0.5 s for polychromatic imaging using the full spectrum of the beam (white beam). The spatial resolution achieved in the experiments was approximately 200 µm. The transmitted monochromatic neutron beam intensity at a wavelength of λ = 0.395 nm was significantly reduced during cooling below the martensitic start temperature M s since the emerging martensitic phase has a ~10% higher attenuation coefficient than the austenitic phase. Neutron imaging was significantly influenced by coherent neutron scattering caused by the thermal motion of the crystal lattice (Debye–Waller factor), resulting in a reduction in the neutron transmission by approx. 15% for monochromatic and by approx. 4% for polychromatic imaging. KW - Neutron radiography KW - Debye–Waller factor KW - Austenite-to-martensite transformation KW - Low transformation temperature (LTT) steel KW - Bragg-edge imaging KW - Gas tungsten arc welding (GTAW) PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-559077 DO - https://doi.org/10.3390/app112210886 VL - 11 IS - 22 PB - MDPI AN - OPUS4-55907 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Bergant, M. A1 - Larrosa, N. A1 - Yawny, A. A1 - Madia, Mauro T1 - Short crack growth model for the evaluation of the fatigue strength of WAAM Ti-6Al-4V alloy containing pore-type defects N2 - The role of defects in the fatigue strength of Wire Arc Additively Manufactured (WAAMed) Ti-6Al-4V is analysed by means of the IBESS model, a fracture mechanics short crack growth approach based on the cyclic R-curve. Pores and crack-like defects are analysed. Estimations of the role of pore shape and size agree well with published fatigue data of WAAM Ti-6Al-4V with pores. The model is also used to explain the effect of fabrication defects on the scatter of experimental data. This demonstrates that short crack growth models represent a suitable engineering tool for the fatigue assessment of defective AM materials. KW - WAAM Ti-6Al-4V KW - Cyclic R-curve KW - IBESS model for short cracks KW - Kitagawa-Takahashi (K-T) diagram PY - 2023 DO - https://doi.org/10.1016/j.engfracmech.2023.109467 SN - 0013-7944 VL - 289 SP - 1 EP - 21 PB - Elsevier Ltd. AN - OPUS4-57963 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Liepold, Philipp T1 - Bewertung der Erstarrungsrissanfälligkeit hochfester Schweißverbindungen mittels MVT-Test N2 - Der modifizierte Varestraint-Transvarestraint-Test (MVT-Test) ist die an der BAM vorherrschende Version des Varestraint-Tests der weltweit Anwendung findet. Die Auswertung des Tests erfolgt durch Messen von Risslängen unter dem Lichtmikroskop. Der Vortrag beleuchtet Theorien über die Aussagekraft der Messung, stellt neue Herangehensweisen vor und vergleicht diese anhand von Beispielen. T2 - BMDK CY - Magdeburg, Germany DA - 24.05.2023 KW - MVT KW - Varestraint PY - 2023 AN - OPUS4-57620 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kromm, Arne T1 - Spannungen beim Schweißen von Bauteilen N2 - Der Vortrag gibt einen Überblick über das Phänomen der Schweißeigenspannungen. Es wird auf die Bedeutung und Entstehungsursachen eingegangen. Mit besonderem Fokus auf die Eigenspannungen beim Schweißen von Komponenten werden Messmöglichkeiten und Anwendungsbeispiele vorgestellt. T2 - Jahresmitgliederversammlung DVS Bezirksverbandes Berlin CY - Berlin, Germany DA - 24.04.2024 KW - Eigenspannungen PY - 2024 AN - OPUS4-59944 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Liepold, Philipp T1 - Anwendung von CNNs zur verbesserten Auswertung von MVT-Tests N2 - Durch die Anwendung von Convolutional Neural Networks (CNNs) kann die Auswertung von Modifizierten Varestraint-Transvarestraint-Tests (MVT) erheblich verbessert werden. Im MVT-Test werden Proben während des Schweißvorgangs über einen Zylinder gebogen. Die auf der Oberfläche der Probe sichtbare Rissstruktur gibt über Parameter wie die Gesamtrisslänge Auskunft über die Erstarrungsrissbeständigkeit der verwendeten Kombination aus Grundstoff, Schweißzusatz und Schweißparametern. Jedoch kann eine Auswertung unter dem Mikroskop sehr aufwendig sein und je nach Beobachter unterschiedliche Ergebnisse liefern. Mit Hilfe von CNNs wird die Auswertung der Risse automatisiert was Genauigkeit, Geschwindigkeit und Vergleichbarkeit verbessert. T2 - BMDK CY - Magdeburg, Germany DA - 05.12.2022 KW - CNN KW - MVT KW - KI PY - 2022 AN - OPUS4-56839 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zhu, Jiangchao A1 - Madia, Mauro A1 - Schurig, M. A1 - Schlums, H. A1 - Zerbst, Uwe T1 - Fracture mechanics-based structural integrity assessment of aeroengine turbine disks under overspeed conditions N2 - Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The actual part qualification and certification procedures make use of spin-tests conducted on productionsimilar disks. While these tests provide, on the one hand, a reliable definition of the critical conditions for real components, on the other hand they represent a relevant cost item for engine manufacturers. The aim of this work is to present part of a fracture mechanics-based procedure under development which aims at replacing the tests on production-similar disks with lab tests on fracture mechanics specimens. In particular, the rimpeeling failure mode is considered as case study. A semi-circular surface crack is modelled at the most stressed region at the diaphragm of a turbine disk, with the crack plane perpendicular to the radial direction. The crack is therefore subjected to a biaxial stress state and grows under increasing rotational speed until it triggers the rim-peeling failure. The finite element simulation of the cracked disk considers the real thermal and mechanical loading conditions. In order to design a lab representative specimen, beside the crack driving force, expressed in terms of � -integral, also the constraint to plastic deformation e.g., stress triaxiality, at the crack-tip must be similar for the same crack in the specimen and in the disk. This has been achieved and as expected, both the highest � -integral and constraint factor are calculated at the same location along the crack front for both disk and specimen. The results of the structural integrity assessment in the form of a Failure Assessment Diagram (FAD) show good agreement between designed specimen and disk both in terms of expected failure mode and value of the critical speed. Probabilistic aspects are also considered in the calculations. T2 - ASME Turbo Expo 2022: Turbomachinery Technical Conference and Exposition (GT2022) CY - Rotterdam, The Netherlands DA - 13.06.2022 KW - Fracture mechanics KW - Burst KW - Turbine disk PY - 2022 SP - 1 EP - 7 PB - ASME AN - OPUS4-55903 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zhu, Jiangchao T1 - Kennwertermittlung für die Bewertung der Integrität einer Turbinenscheibe bei Überdrehzahl N2 - Turbinenscheiben sind thermisch und mechanisch hochbeanspruchte, sicherheitsrelevante Komponenten in Gasturbinen. Ihre Integrität wird in Bauteiltests unter Überdrehzahlbedingungen nachgewiesen. Kontext des Aufsatzes ist die Erarbeitung einer zusätzlichen Bewertungsebene auf der Grundlage von Versuchen unter monotoner Beanspruchung, die die Beanspruchung im Bauteil realistisch wiedergeben soll. Dazu werden zwei Typen von bruchmechanischen Proben anwendungsnah ausgelegt und aus einer Turbinenscheibe ausgeschnitten: Der erste Typ ist eine biaxiale Probe, die die Beanspruchung und den Dehnungsbehinderungszustand am Diaphragm der Turbinenscheibe abbildet, die zweite eine bruchmechanische Probe, die die einachsige Beanspruchung und den Dehnungsbehinderungszustand am Bore der Turbinenscheibe wiedergibt. Im Rahmen eines Schadentoleranzansatzkonzepts ist anschließend jeweils ein halbelliptischer Riss an den genannten Stellen der Turbinenscheibe zu betrachten. Mittels numerischer Berechnungen wird ein kritischer Punkt auf der Rissfront des Risses am Diaphragm bestimmt, dort wo die höchste Rissspitzenbelastung (J-Integral) auftritt. Auf der Basis der Rissspitzenbelastung, des Dehnungsbehinderungszustands und des entsprechenden Spannungsverhältnisses an diesem kritischen Punkt wird eine Kreuzprobe mit einem Durchriss konzipiert, die diese Verhältnisse im Bauteil widerspiegelt. Die Versuche werden unter der Temperatur am Diaphragm der Turbinenscheibe durchgeführt. Die J-R-Kurve und die plastische Kollapsgrenze werden bestimmt. Auch die einachsigen Versuche werden unter der Temperatur am Bore der Turbinenscheibe durchgeführt. Die Zugprobe enthält halbelliptische Oberflächenrisse. Ähnlich wie bei der Auslegung der Kreuzproben werden die Rissspitzenbelastung, der Dehnungsbehinderungszustand und das Spannungsverhältnis vergleichbar mit der Turbinenscheibe eingestellt. Die J-R-Kurve und die plastische Kollapsgrenze werden bestimmt. Mit den Versuchsergebnissen werden die kritischen Lasten für verschiedene Versagensmechanismen (instabiles Risswachstum, plastischer Kollaps) der bruchmechanischen Proben ermittelt, die der kritischen Überdrehzahl der Turbinenscheibe entsprechen. T2 - 40. Vortrags- und Diskussionstagung Werkstoffprüfung 2022 CY - Dresden, Germany DA - 27.10.2022 KW - Turbine disk KW - Fracture mechanics KW - Biaxial test KW - Burst PY - 2022 AN - OPUS4-56148 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Strauß, Lea T1 - Empirical Model for Fatigue Life Prediction N2 - Laser-based powder bed fusion (PBF-LB) is an advanced additive manufacturing technique renowned for its precision and capability to fabricate complex metal components. However, the high thermal gradients and rapid cooling rates intrinsic to this process introduce significant process-induced effects, such as inhomogeneities, surface roughness, anisotropy, and residual stress, all of which critically influence the fatigue behavior of the produced parts. This study investigates the fatigue performance of AlSi10Mg samples produced by PBF-LB, examining the impact of varying surface conditions, geometries, and residual stress levels. Fatigue life prediction models are formulated based on nominal stress amplitude, residual stress, notch factor, crackinitiating inhomogeneity, and surface roughness, with smooth samples serving as a baseline reference. The study presents two empirical models for predicting fatigue life and fatigue strength using S-N curves and the Kitagawa-Takahashi diagram with the El Haddad approach, derived from comprehensive experimental data, including finite element modelling, fatigue life measurements, surface roughness evaluations, and residual stress analysis. T2 - ICAM2024 CY - Atlanta, GA, USA DA - 28.10.2024 KW - AlSi10Mg KW - Kitagawa-Takahashi diagram KW - Equivalent stress KW - Fatigue life prediction KW - PBF-LB/M PY - 2024 AN - OPUS4-61538 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Fatigue Strength of Aerospace Parts Repaired by Cold Spray N2 - Aerospace components are safety critical parts, which are often replaced when found defective after the fabrication process or after periodic inspection in-service. Cold spray repair is a promising and cost-saving alternative to replacing worn parts. Depositing materials in decent quality fill machined damage volumes can enhance the performance of refurbished parts and extend their working life. Furthermore, repair represents a resource-efficient and green process in a world targeting at decarbonization of many industrial sectors. Component repair consists of a defined sequence of operations. First, damage is removed by machining, then new material is applied by cold spray on the machined substrate. Usually, the original functional shape of the component is restored by machining. Post-spraying heat treatments can be applied where required. Despite the advantages, cold spray repair still suffers from major limitations which prevent its application in safety relevant parts. The main challenges are posed by the poor adhesion strength, the porosity inherent in the manufacturing process, the reduced ductility and the presence of residual stresses. This work presents recent results obtained in the frame of the cluster project CORE devoted to the development of automatized repair of aerospace parts by cold spray. The investigations consider high-strength aluminum alloys typically used in structural applications in the aerospace industry. As the fatigue properties are crucial to the safe application of repaired components, and given the presence of process-induced defects, a damage tolerant framework is peculiarly suitable for the structural integrity assessment of repaired commponents and give an indication of the permissible defects to optimize the parameters of the cold spray process. Several high cycle fatigue and fatigue crack propagation tests have been performed to compare the fatigue performance of base and repaired materials. The mechanical tests are corroborated by fractographic and microstructural investigations. T2 - ICAM2024 CY - Atlanta, GA, USA DA - 28.10.2024 KW - Cold Spray KW - Aerospace KW - Repair KW - Structural Integrity KW - Fatigue Strength PY - 2024 AN - OPUS4-61539 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kardjilov, Nikolay T1 - Neutron Thermo Tomography N2 - This study presents an investigation of the neutron transmission signal as a function of martensitic steel sample temperature and phase transformation during a welding process. A theoretical description that includes the Debye-Waller factor was used to describe the temperature influence on the neutron cross-sections. Neutron imaging using a monochromatic beam helps to observe transmission variations related to the martensitic-austenitic phase transformations before the Bragg-edge and to the material temperature above the Bragg-edge. In-situ neutron imaging of welding experiments show the distribution of the phase transformation and of the temperature in bulk steel samples. The performed finite element modelling of expected temperature distributions shows good agreement with the obtained experimental data. T2 - Neutron Wavelength-Dependent Imaging Workshop (NEUWAVE-12) CY - Lund, Sweden DA - 01.09.2024 KW - Neutron Imaging KW - Energy Selective KW - Neutron Thermo Tomography PY - 2024 AN - OPUS4-61265 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kromm, Arne T1 - Möglichkeiten zur Optimierung von schweißbedingten Beanspruchungen durch Einsatz von LTT-Zusatzwerkstoffen N2 - Der Vortrag gibt einen Überblick zum Thema Low Transformation Temperature (LTT) Zusatzwerkstoffe. Es wird gezeigt, wie mit einem Experiment unter Nutzung von Sychrotronstrahlung das Phänomen der Umwandlungsplastizität untersucht werden kann. T2 - 12. Vollversammlung des SFB 1120: Summer School 2024 CY - Steinfeld (Kall), Germany DA - 11.06.2024 KW - Eigenspannungen KW - LTT-Zusatzwerkstoffe KW - Hochfester Stahl PY - 2024 AN - OPUS4-60259 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Griesche, Axel T1 - Crystallographic phase transformations and corresponding temperature distributions during gtaw of supermartensitic stainless steel visualized by nbei N2 - We investigated the phase transformations during butt-welding of supermartensitic steel plates with help of Neutron-Bragg-Edge Imaging (NBEI). Gas tungsten arc welding (GTAW) was used with a motorized torch allowing for automated weldments. The austenitization in the heat affected zone (HAZ) could be clearly visualized at λ = 0.39 nm, a wavelength smaller than the Bragg edge wavelengths of both austenite and martensite. The re-transformation into the martensitic phase during cooling was clearly detected. However, we observed an unexpected additional change in transmission at λ = 0.44 nm, a wavelength larger than the wavelength of the Bragg edges of both the martensitic and austenitic phases. We attribute this change to the Deybe-Waller-Factor that describes the temperature dependence of coherent scattering at a crystal lattice. The observed two-dimensional attenuation map corresponds well with a temperature distribution modelling by software macros in ANSYS [3]. Here, the absolute temperature values could be achieved by calibrating the modelled attenuation with help of a thermocouple placed at the steel plate. This allows in return for a direct two-dimensional temperature reading based on the Debye-Waller-relation between neutron attenuation and sample temperature. T2 - WCNR-12 CY - Idaho Falls, Id, USA DA - 02.06.2024 KW - Neutron KW - Radiography KW - Welding PY - 2024 AN - OPUS4-60242 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kromm, Arne T1 - Best practice: How to work with a mobile diffractometer N2 - Beginning with a general overview about resdiual stress determination by X-ray diffraction, the presentation is focussing on some does and dont's when working with a portable diffractometer. T2 - European Conference on Residual Stresses 11 - Tutorial 1: Residual stresses in additive manufacturing CY - Prague, Czech Republic DA - 03.06.2024 KW - Residual stress KW - X-ray diffraction PY - 2024 AN - OPUS4-60287 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa A1 - Madia, Mauro A1 - Kanna, Naveen A1 - Bär, Jürgen ED - Ricoeur, Andreas T1 - Anwendung der zyklischen R-Kurven-Analyse zur Abschätzung des Kitagawa-Takahashi-Diagramms N2 - Die ausgeprägte Langzeitfestigkeit eines Werkstoffes entspricht der maximalen Spannung, unterhalb derer alle ursprünglich wachstumsfähigen Mikrorisse arretieren. Für fehlerbehaftete Werkstoffe stellt das Kitagawa-Takahashi (KT)-Diagramm die Abhängigkeit der ausgeprägten Langzeitfestigkeit von der Defektgröße dar. Das KT-Diagramm kann mit großem Aufwand experimentell bestimmt oder durch verschiedene Modelle abgeschätzt werden. Solche Ansätze ergeben oft nichtkonservative Prognosen und berücksichtigen weder den Aufbau der Rissschließeffekte noch lokale Spannungen. In dieser Arbeit wird ein Kurzrissmodell auf Grundlage der zyklischen R-Kurve und des Rissarrestphänomens zur Abschätzung des KT-Diagramms vorgestellt. Die Abschätzungen werden mit experimentellen Daten validiert, die mit gekerbten Proben nach dem Treppenstufenverfahren ermittelt wurden. T2 - 57. Tagung des DVM-Arbeitskreises Bruchmechanik und Bauteilsicherheit CY - Köln, Germany DA - 18.02.2025 KW - Langzeitfestigkeit KW - KT-Diagramm KW - zyklische R-Kurven-Analyse PY - 2025 DO - https://doi.org/10.48447/BR-2025-512 VL - 257 SP - 93 EP - 104 PB - Deutscher Verband für Materialforschung und -prüfung e.V. CY - Berlin, Deutschland AN - OPUS4-62603 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Strauß, Lea A1 - Duarte, Larissa A1 - Kruse, Julius A1 - Madia, Mauro A1 - Löwisch, Günther T1 - An equivalent stress approach for predicting fatigue behavior of additively manufactured AlSi10Mg N2 - Laser-based powder bed fusion (PBF-LB) is an advanced additive manufacturing technique renowned for its precision and capability to fabricate complex metal components. However, the high thermal gradients and rapid cooling rates intrinsic to this process introduce significant process-induced effects, such as inhomogeneities, surface roughness, anisotropy, and residual stress, all of which critically influence the fatigue behavior of the produced parts. This study investigates the fatigue performance of AlSi10Mg samples produced by PBF-LB, examining the impact of varying surface conditions, geometries, and residual stress levels. Fatigue-life prediction models are formulated based on nominal stress amplitude, residual stress, form factor, crack-initiating inhomogeneity, and surface roughness, with smooth samples serving as a baseline reference. The study presents two empirical models for predicting fatigue life and fatigue strength using S–N curves and the Kitagawa–Takahashi diagram with the El Haddad approach, derived from comprehensive experimental data, including finite element modeling, fatigue-life measurements, surface roughness evaluations, and residual stress analysis. KW - AlSi10Mg KW - Kitagawa–Takahashi diagram KW - El Haddad KW - Equivalent stress KW - Fatigue-life prediction KW - PBF-LB/M PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-625176 DO - https://doi.org/10.1007/s40964-025-00974-0 SP - 1 EP - 16 PB - Springer Science and Business Media LLC AN - OPUS4-62517 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hilgenberg, Kai A1 - Madia, Mauro T1 - Additive Fertigung von Bauteilen und Strukturen – Grenzen, Risiken, Chancen N2 - Dieser Eröffnungsvortrag des DVM-Tages beleuchtet Herausforderungen in der additiven Fertigung und plädiert für eine enge Zusammenarbeit von Fertigungstechnik und Bruchmechanik für die Vorhersage der Lebensdauer AM-gefertigter Komponenten. T2 - DVM-Tag CY - Berlin, Germany DA - 08.04.2025 KW - Additive Fertigung KW - Digitale Qualitätssicherung KW - Ermüdungsfestigkeit PY - 2025 AN - OPUS4-62971 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Werner, Tiago T1 - Kurzrisswachstum in additiv gefertigtem austenitischem Edelstahl 316L N2 - Diese Untersuchung beschäftigt sich mit der Charakterisierung von Kurzrisswachstum in mittels Laser-Pulverbett-Verschmelzen (LPBF - Laser Powder Bed Fusion) hergestelltem rostfreien austenitischen Stahl. Spezifischer wird die Ermittlung zyklischer R-Kurven untersucht. Diese beschreiben den Aufbau des Widerstands gegen Ermüdungsrisswachstum - d.h. des Schwellenwertes - aufgrund von Rissschließeffekten bei physikalisch kurzen Rissen. Mit Hilfe der zyklischen R-Kurven kann die Fähigkeit eines Bauteils, physikalisch kurze Risse zu arretieren, charakterisiert werden. Wir verfügen damit über eine Schnittstelle zwischen klassischer Ermüdung und Bruchmechanik. Das ist gerade auch für additiv gefertigte (AM – Additive Manufacturing) Materialien von Interesse. Diese weisen prozessintrinsische Defekte auf, die als Initiierungsstellen kurzer Ermüdungsrisse agieren. Im Rahmen der experimentellen Untersuchungen wurden zyklische R-Kurven für konventionellen und LPBF AISI-316L-Stahl ermittelt. Insbesondere wurde der Einfluss verschiedener Wärmebehandlungen (WB1: 450°C, WB2: 800°C und WB3: 900°C) auf das Wachstumsverhalten physikalisch kurzer Risse im LPBF-Material untersucht. Aufgrund hoher Eigenspannungen war die Ermittlung des Kurzrisswachstumsverhaltens bei WB1 nicht möglich. Für WB2 und WB3 ergaben sich sehr unterschiedliche zyklische R-Kurven. Untersuchungen der Eigenspannungen, der Bruchfläche (insbesondere der Rauheit) und der Mikrostruktur sollen die Ursachen für das unterschiedliche Verhalten erklären. Die Ergebnisse werden mit den Verhältnissen in konventionellem Material verglichen. T2 - 41. Werkstoffmechanikseminar TU Darmstadt CY - Online meeting DA - 26.10.2020 KW - AM KW - Additiv KW - Zyklische R-Kurve KW - 316L KW - Ermüdung KW - Ermüdungsrisswachstum KW - Risswachstum PY - 2020 AN - OPUS4-51603 LA - mul AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Ermittlung des intrinsischen Schwellenwerts und dessen Validierung als Werkstoffparameter N2 - Die schadenstolerante Bewertung von zyklisch beanspruchten Bauteilen auf bruchmechanischer Grundlage ist von großer praktischer Bedeutung, insbesondere für die Spezifizierung von Inspektionsintervallen. Eine Schwachstelle der gegenwärtigen Vorgehensweise bildet der nur ungenügend verstandene Schwellenwertbereich der da/dN-ΔK -Kurve. Relevant ist das deshalb, weil viele Bauteile bei Lasten betrieben werden, die in eben diesen Bereich fallen. Der Vortrag beschäftigt sich mit Unsicherheiten bei der Ermittlung des Schwellenwertes, mit Einflussparametern, die dabei zu berücksichtigen sind, und mit einem Vorschlag zur konservativen Einbeziehung des Schwellenwertbereichs in die Bauteilauslegung. Der Schwellenwert gegen Ermüdungsrissausbreitung ist als der zyklische Spannungsintensitätsfaktor definiert, unterhalb dessen kein Risswachstum mehr stattfindet. Dabei ist zu beachten, dass der Wert in der konventionellen da/dN-ΔK -Kurve auf Langrisswachstum beschränkt ist und, strenggenommen, auch das nur dann, wenn das Rissschließphänomen voll ausgebildet ist. Unter Rissschließen versteht man das Schließen des zyklisch beanspruchten Risses in der Regel oberhalb des Nulldurchgangs der Last. Wichtige Rissschließmechanismen sind das plastizitäts-, das rauheits- und das oxid-induzierte Schließen wobei die beiden letztgenannten im Schwellenwertbereich dominierend sind. Der Schwellenwert selbst besteht aus zwei Anteilen, einem intrinsischen, der von den elastischen Konstanten und vom Gittertyp abhängt und einem extrinsischen, der mit dem Aufbau der Rissschließeffekte zusammenhängt und von Parametern wie der Mikrostruktur, dem Spannungsverhältnis aus Unter- und Oberlast und der Risstiefe beeinflusst wird. In Fällen, bei denen oxid-induziertes Rissschließen eine Rolle spielt, hängt der erhaltene Wert des Schwellenwerts vom experimentellen Verfahren ab, wobei die konventionelle Lastabsenkung nach Standard nicht-konservative Werte ergeben kann. Der Vortrag thematisiert die unterschiedlichen Optionen der experimentellen Ermittlung mit besonderem Fokus auf dem intrinsischen Schwellenwert und, davon ausgehend, die Anbindung an den rissschließkorrigierten Paris-Bereich der da/dN-ΔK -Kurve. T2 - Werkstoffmechanikseminar 2020 CY - Online meeting DA - 26.10.2020 KW - Intrinsischer Schwellenwert gegen Ermüdungsrissausbreitung KW - Schadenstolerante Bauteilauslegung KW - Restlebensdauer PY - 2020 AN - OPUS4-51604 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Der Schwellenwert der da/dN-∆K-Kurve als Auslegungskriterium für die Bauteilbewertung N2 - Für die Bestimmung der Restlebensdauer zyklisch beanspruchter Bauteile kommt dem Schwellenwert für Ermüdungsrissausbreitung ΔKth und dem sich anschließenden Schwellenwertbereich der dadN⁄-ΔK-Kurve große Bedeutung zu. Dem stehen Unsicherheiten bei der Bestimmung und Analyse gegenüber. Der Aufsatz befasst sich mit der Ermittlung des sogenannten intrinsischen Schwellenwerts, der als robuster Eingangsparameter für eine „rissschließfreie“ Analyse der Restlebensdauer von entscheidender Bedeutung ist. T2 - Tagung Werkstoffprüfung 2020 CY - Online meeting DA - 03.12.2020 KW - Intrinsischer Schwellenwert gegen Ermüdungsrissausbreitung KW - Schadenstolerante Bauteilauslegung KW - Restlebensdauer PY - 2020 AN - OPUS4-51754 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Werner, Tiago T1 - Short fatigue crack propagation in L-PBF 316L stainless steel N2 - Fracture mechanics is a key to fatigue assessment in AM metal components. Short fatigue cracks are initiated at defects and pronounced surface roughness intrinsic to AM. The subsequent crack-propagation is strongly influenced by microstructural interactions and the build-up of crack-closure. The aim of the present study is to give an insight into short-crack propagation in AM-metals. Fatigue crack propagation resistance curves were determined experimentally for AISI 316L manufactured by Laser Powder Bed Fusion (L-PBF) which was heat treated at three different temperatures. Differences in the build-up of the fatigue-crack propagation threshold in between the L-PBF specimens and compared to wrought material are due to the residual stress states, a pronounced roughness of the crack-faces in the L-PBF specimens and phase transformation in the vicinity of the crack-tip, resulting in increased crack-closure. This, together with crack-branching found along the crack path, enhances the resistance to the propagation of fatigue cracks. T2 - ASTM International Conference on Additive Manufacturing 2020 CY - Online meeting DA - 16.11.2020 KW - Additive Manufacturing KW - Cyclic R-Curve KW - Component assessment KW - L-PBF KW - 316L KW - Residual Stress KW - Fatigue Crack Growth PY - 2020 AN - OPUS4-51585 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Einflussfaktoren auf die Bestimmung von Rissfortschrittsdaten N2 - Rissfortschrittsdaten sind notwendig für die bruchmechanische Bewertung zyklisch beanspruchter Bauteile. Deren zuverlässige experimentelle Ermittlung wird von verschiedenen Faktoren beeinflusst, was wiederum zur Unsicherheit bei der Restlebensdauerprognose führen kann. Der Vortrag befasst sich mit der Untersuchung der Einflussfaktoren auf die Ermittlung von Rissfortschrittsdaten. Eine Prozedur zur Berechnung der Restlebensdauer wird eingeführt, die auf rissschließfrei Rissfortschrittsdaten basiert. T2 - 42. Werkstoffmechanikseminar 2021 CY - Online meeting DA - 11.10.2021 KW - Rissfortschrittsdaten KW - Einflussfaktoren KW - Restlebensdauerprognose PY - 2021 AN - OPUS4-53615 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Giese, Marcel T1 - Experimentelle Charakterisierung der WIG-Schweißeignung einer Hoch- und Mediumentropie-Legierung N2 - Equiatomic multi-element systems with defined entropy are a relatively new mate-rial concept for alloy production. These alloys consist of at least five elements in equiatomic distribution in the case of high entropy alloys (HEA) and three to four elements in equiatomic distribution in the case of medium entropy alloys (MEA). Previous studies on these alloys have focused primarily on their production, micro-structure and the resulting material properties. Meanwhile, the focus here is on the processing of the alloys and their influence on future applications. Up to now, there has been insufficient knowledge of the materials and processes involved in weld-ing. In this work, therefore, the weldability of a CoCrFeMnNi-HEA and a CoCrNi-MEA by means of a TIG welding process was investigated as a basic system. To this end, the welding parameters were first determined on a reference alloy (Ni-based: 2.4858) and transferred to the welding of the CoCrFeMnNi-HEA and CoCrNi-MEA. Weldability was assessed by testing the absence of defects and microstructures obtained. The weld metal exhibited the dendritic microstructure typical of TIG, with microsegregations forming as interdendritic phases. Increased hardness was de-tected in the weld metal compared to the base metal. In the heat-affected zone, there was little grain growth and, in both alloys, the formation of hot cracks after welding. The cause of the cracks was to be found in the specimen preparation, which had an influence on the subsequent processing. After elimination of this in-fluence, no welding process-related imperfections were found in the CoCrFeMnNi-HEA and CoCrNi-MEA. In summary, both materials show good fusion weldability by TIG welding. The re-sults of this work thus contribute to the understanding of the weldability of HEA and in particular for CoCrNi-MEA, which was considered in this depth for the first time. T2 - Verteidigung Masterarbeit Otto von Guericke Universität Magdeburg CY - Magdeburg, Germany DA - 20.10.2021 KW - Hochentropielegierung KW - Mediumentropielegierung KW - WIG-Schweißen PY - 2021 AN - OPUS4-53643 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Investigation on the influence of different testing methods and parameters on the determination of fatigue crack growth data N2 - The correct determination of fatigue crack propagation data is of great importance for the damage tolerance design of engineering components, especially with regard to the calculation of residual lifetime and the establishment of inspection intervals. The fatigue crack propagation threshold Δ𝐾th, in this respect, is a crucial input parameter for simulating crack growth, since it corresponds to the stress intensity factor range at which a non-growing crack starts to propagate. However, the experimental determination of Δ𝐾th, as well as its application, is still confronted with few issues related among others to the load ratio (R) dependency of Δ𝐾th, the testing procedure, and environmental effects. These can lead to large scatter and significant errors in the prediction of component failure. In this context, the use of the intrinsic fatigue crack propagation threshold Δ𝐾th,eff in component assessment is a promising alternative, since it does not depend on a number of factors that affect Δ𝐾th, but only on the elastic properties (𝐸-modulus) and the lattice (Burger’s vector ‖𝑏‖) of the material. The aim of the present work is therefore to investigate different experimental procedures for the determination of Δ𝐾th,eff, namely: (a) conventional load reduction (LR) procedures, (b) the 𝐾max procedure and (c) compression pre-cracking load reduction and constant amplitude (respectively CPLR and CPCA) methods. Furthermore, the determination of Δ𝐾th has been carried out varying some testing parameters, such as test frequency, Δ𝐾 at the beginning of the crack propagation test (Δ𝐾0) and stress ratio (R). The results are statistically analyzed and a discussion about the use of Δ𝐾th and Δ𝐾th,eff for the component fatigue assessment is presented. T2 - 6th. International Virtual Conference of Engineering Against Failure CY - Online meeting DA - 23.06.2021 KW - Crack closure KW - Damage tolerance assessment KW - Residual lifetime KW - Intrinsic fatigue crack propagation threshold PY - 2021 AN - OPUS4-52899 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Vergleichende Untersuchungen zum intrinsischen Schwellenwert der da/dN-∆K Kurve N2 - Für die Bestimmung der Restlebensdauer zyklisch beanspruchter Bauteile kommt dem Schwellenwert für Ermüdungsrissausbreitung, Δ𝐾𝑡ℎ, und dem sich anschließenden Schwellenwertbereich der 𝑑𝑎𝑑𝑁⁄−Δ𝐾-Kurve große Bedeutung zu. Dem stehen Unsicherheiten bei der Bestimmung und Analyse gegenüber. Der Aufsatz befasst sich mit der Ermittlung des sogenannten intrinsischen Schwellenwerts, der als robuster Eingangsparameter für eine „rissschließfreie“ Analyse der Restlebensdauer von entscheidender Bedeutung ist. T2 - DVM-Arbeitskreis „Bruchmechanik und Bauteilsicherheit“ 2021 CY - Online meeting DA - 18.02.2021 KW - Schadenstolerante Bauteilauslegung KW - Restlebensdauer KW - Intrinsischer Schwellenwert gegen Ermüdungsrissausbreitung PY - 2021 AN - OPUS4-52263 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - The effect of the environmental conditions on the threshold against fatigue crack propagation N2 - The threshold against fatigue crack propagation (ΔKth) is a crucial parameter for the damage tolerance assessment of engineering components subjected to cyclic loading and it is composed by two distinct components, one intrinsic, dependent on the elastic material properties and the lattice type, and one extrinsic, related to the occurrence of crack closure effects. An important issue is that several factors can influence ΔKth and, in general, the fatigue crack propagation behavior. In this work, the influence of the experimental procedure, air humidity and test parameters on da/dN-ΔK data has been investigated. Results are discussed with their potential causes and consequences on the calculations of the residual lifetime. T2 - Conference Fatigue Design 2021 CY - Online meeting DA - 17.11.2021 KW - Fatigue crack propagation threshold KW - Crack closure effect KW - Experimental procedure KW - Environmental conditions PY - 2021 AN - OPUS4-53770 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Estimation of the Kitagawa-Takahashi diagram by cyclic R-curve analysis N2 - The Kitagawa-Takahashi (KT) diagram is a proven concept for describing the fatigue limit in presence of a defect or crack. It can be determined empirically with great experimental effort. It can also be estimated by means of the El Haddad relationship if the endurance limit and the long fatigue crack propagation threshold are available in reasonable accuracy. A third option is the determination using the cyclic R-curve, which describes the dependency of the fatigue crack propagation threshold on the crack growth at the short crack propagation stage. This can be experimentally determined using a closure-free initial pre-crack. It can then be applied to the determination of crack arrest for a given applied load and a given defect or crack size. Compared to the other two methods mentioned above, this option has considerable advantages: It can be applied to any component and any stress ratio. It allows the treatment of multiple cracks and provides estimations of the S-N curve in the finite life regime as well as at the endurance limit. Compared to the empirical determination of the KT diagram, the experimental effort is significantly lower and compared to the El Haddad approach it avoids problems such as the use of non-conservative long fatigue crack propagation thresholds (when the conventional load reduction method is applied to materials prone to corrosion) and the mathematical predetermination of the curve shape. The work introduces the method and provides a critical discussion as well as quantitative comparison between the different methods. T2 - Fatigue Design 2021 CY - Online meeting DA - 17.11.2021 KW - Fatigue life KW - Endurance limit KW - Kitagawa-Takahashi diagram KW - Cyclic R-curve PY - 2021 AN - OPUS4-53778 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schönherr, J. A. T1 - Robust Determination of Fatigue Crack Propagation Thresholds from Crack Growth Data N2 - To assess the ability of cracks to grow, a robust determination of the threshold against fatigue crack propagation ∆Kth is of paramount importance. The standards ASTM E647 and ISO 12108 introduce operational definitions of ∆Kth based on the crack propagation rate da/dN. For evaluating ∆Kth, both suggest fitting a linear function to a defined subset of the logarithmic ∆K – da/dN test data, where ∆Kth follows by evaluating the linear function at da/dN = 10-7 mm/cycle and da/dN = 10-8 mm/cycle, respectively. In general, this kind of fit suffers from a bad representation of the actual curvature of the crack propagation curve. Therefore, we propose a robust method for evaluating ∆Kth using a non-linear function that reduces the artificial conservativeness induced by the evaluation method as well as the susceptibility to scatter in test data and the influence of test data density. The method is calibrated against a large set of S690QL crack growth data obtained from a total of 48 specimens, and validated against a set of S355NL and S960QL data (3 specimens each), obtained as a part the IBESS (integral fracture mechanics determination of the fatigue strength of welds) project. T2 - ECF23 (European Conference on Fracture 2022) CY - Madeira, Portugal DA - 27.06.2022 KW - Fatigue crack propagation threshold KW - ISO 12108 KW - ASTM E647 KW - Data evaluation methods KW - Experimental determination PY - 2022 AN - OPUS4-55252 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Zhu, Jiangchao T1 - Bruchmechanische Bewertung der Integrität einer Turbinenscheibe bei Überdrehzahl N2 - Turbinenscheiben sind thermisch und mechanisch hochbeanspruchte, sicherheitsrelevante Komponenten in Gasturbinen. Ihre Integrität wird in Bauteiltests unter Überdrehzahlbedingungen nachgewiesen. Kontext des Aufsatzes ist die Erarbeitung einer zusätzlichen Bewertungsebene auf der Grundlage von Versuchen unter monotoner Beanspruchung, die die Beanspruchung im Bauteil realistisch wiedergeben soll. Betrachtet wird ein halbelliptischer Riss, der bei der weiteren Ausbreitung als Umfangsriss wächst (rim peeling). Die Simulation dieser Stelle im Bauteil schließt die mechanische und thermische Beanspruchung sowie sie Dehnungsbehinderung ein. Letztere wird anhand zweier Parameter, der Spannungsmehrachsigkeit ℎ und des (allerdings modifizierten) Constraint-Parameters nach Newman, der die Spannungen über den plastisch verformten Bereich mittelt, bestimmt. Erwartungsgemäß zeigt sich, dass die höchste Dehnungsbehinderung weder an den Oberflächenpunkten, noch an den tiefsten Punkten, sondern an einer Stelle zwischen beiden auf der Rissfront auftritt. Als Versuchsgeometrie für die monotonen Tests soll eine Kreuzprobe mit wanddurchdringenden Rissen ausgehend von einer Innenbohrung dienen. Durch geeignete Wahl der Risstiefe sowie der in beiden Richtungen angreifenden Kräfte gelingt es, bauteiladäquate Zustände zu erzeugen. T2 - 54. Tagung des Arbeitskreis Bruchmechanik und Bauteilsicherheit CY - Online meeting DA - 22.02.2022 KW - Struktur Integrität KW - Turbinenscheibe KW - Constraint KW - Bruchmechanik PY - 2022 AN - OPUS4-54402 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Pfretzschner, Beate A1 - Schaupp, Thomas A1 - Hannemann, Andreas A1 - Schultz, Michael A1 - Griesche, Axel T1 - On the Genesis of Artifacts in Neutron Transmission Imaging of Hydrogenous Steel Specimens N2 - Hydrogen-charged supermartensitic steel samples were used to systematically investigate imaging artifacts in neutron radiography. Cadmium stencils were placed around the samples to shield the scintillator from excessive neutron radiation and to investigate the influence of the backlight effect. The contribution of scattered neutrons to the total detected intensity was investigated by additionally varying the sample-detector distance and applying a functional correlation between distance and intensity. Furthermore, the influence of the surface roughness on the edge effect due to refraction was investigated. KW - Refraction KW - Neutron imaging KW - Hydrogen KW - Supermartensitic steel KW - Backlight KW - Scattering PY - 2020 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-506587 DO - https://doi.org/10.3390/jimaging6040022 VL - 6 IS - 22 SP - 1 EP - 10 PB - MDPI CY - Basel, Switzerland AN - OPUS4-50658 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Vecchiato, Luca T1 - Fatigue limit estimation of welded joints under constant amplitude uniaxial loading adopting the cyclic R-curve analysis N2 - Most of the in-service failures of welded structures are due to fatigue damage occurring in the joints. Damage tolerant approaches based on the principles of Fracture Mechanics have been shown to play a key role in this framework, as the fatigue limit is defined by the non-propagating condition of multiple defects at the weld toe. The fatigue limit assessment can be performed using the cyclic R-curve analysis which consists in comparing the driving force of a crack propagating into a component, which depends on the geometry, material and external loads, with its resistance curve, i.e. the cyclic R-curve. The crack propagation occurs whenever the crack driving force is higher than the resistance to fatigue crack propagation, while the crack is arrested in the opposite case. Consequently, this suggests that the fatigue limit of a component is defined as that stress level at which the crack driving force curve is tangent to the crack resistance curve. In the present work, the cyclic R-curve analysis has been adopted for determining the fatigue limit of stress-relieved transverse non-load-carrying joints made of S355 structural steel and subjected to fatigue axial loadings. Experimental tests have been performed to evaluate the fatigue limit of the joints. The driving force, identified by the applied Stress Intensity Factor (SIF), has been evaluated by means of linear elastic finite element analysis taking advantage of the Peak Stress Method for its rapid estimation. Based on the experimental observations that the crack initiation and early crack growth phases in welded joints occur within the Heat Affected Zone (HAZ) the cyclic R-curve has been experimentally derived for both the base metal and HAZ material. T2 - European Conference on Fracture 2022 (ECF23) CY - Funchal, Portugal DA - 27.06.2022 KW - Welded Joints KW - Fatigue Limit KW - Cyclic R-curve PY - 2022 AN - OPUS4-55254 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Fraucture mechanics-based probablistic structural integrity assessment for aero-engine turbine disk N2 - Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The aim of this work is to present part of a fracture mechanics-based probabilistic assessment procedure under development which aims at calculating the critical rotational speed of the turbine disk based on the numerical-analytical solutions and regulations for the failure probability. In particular, the rim-peeling failure mode is considered as case study. A semi-circular surface crack is modelled at the most stressed region at the diaphragm of a turbine disk. In order to design a lab representative specimen, beside the crack driving force, expressed in terms of J-integral, also the constraint to plastic deformation e.g., stress triaxiality, at the crack-tip must be similar for the same crack in the specimen and in the disk. The analytical solutions to calculate the crack driving force for the lab representative specimen are used for the Monte Carlo simulations, the result of which has been assessed in the form of a Failure Assessment Diagram (FAD). The results of the probabilistic structural integrity assessment show good agreement between Monte Carlo simulations and certification values for the disk in terms of expected failure mode and value of the critical speed. T2 - ICF15 - International Conference on Fracture CY - Atlanta, GA, USA DA - 12.06.2023 KW - Fracture Mechanics KW - Failure Assessment Diagram KW - Finite Element Analysis KW - Component Assessment PY - 2023 AN - OPUS4-57727 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Probabilistic structural integrity assessment of welded joints N2 - The fatigue assessment of welded joints requires several input data, which can be subdivided into three categories: geometry, material and loading. The number of input data depends essentially on the complexity of the models employed and on the level of accuracy of the analysis. It is common practice to use safety factors in design to account for the scatter of the input parameters. Nevertheless, overly-conservative factors lead often to unrealistic estimations of fatigue life. This work presents a fracture mechanics-based model for the structural integrity assessment of welded joints under constant amplitude fatigue loading, in which the local geometry at the weld toe and the fatigue crack growth properties are considered statistically distributed. The approach is validated against a large number of experimental data. T2 - ICF15 - International Conference on Fracture CY - Atlanta, GA, USA DA - 12.06.2023 KW - Fatigue KW - Fracture Mechanics KW - Weldments KW - Short crack KW - Probabilistic Assessment PY - 2023 AN - OPUS4-57726 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Progress in the determination of the fatigue propagation resistance in metals and its application to fatigue assessment N2 - This plenary lecture aims at showing the progress in the experimental determination of the fatigue propagation resistance in metals and its application to fatigue assessment. In particular, different new experimental techniques are introduced, which allow a better description of the crack propagation resistance from short to long crack regime. These data can be then applied in the fatigue assessment to predict the fatigue limit and the total life of metallic components. T2 - 5th Iberian Conference on Structural Integrity CY - Coimbra, Portugal DA - 30.03.2022 KW - Crack propagation resistance KW - Cyclic R-Curve KW - Fatigue assessment KW - Kitagawa-Takahashi diagram KW - S-N diagram PY - 2022 AN - OPUS4-54603 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Teske, Tanita T1 - Untersuchung des Potentials des Kaltgasspritzens für die Reparatur zyklisch belasteter Bauteile N2 - Das Kaltgasspritzen als Reparaturverfahren bietet die Möglichkeit den teuren Austausch beschädigter Bauteile in der Luft- und Raumfahrt zu vermeiden. In dieser Arbeit wurden das Potential an der Aluminiumlegierung AL6061-T6, unter Verwendung von Stickstoff als Prozessgas, untersucht. Mit Fokus auf das In-situ Kugelstrahlen, zur Verbesserung der mechanischen Eigenschaften, wurden quasi-statische Zugversuche und einachsige Zeitfestigkeitsversuche durchgeführt. Im Ergebnis zeigte sich die Verbesserung der Adhäsion zwischen Grundwerkstoff und aufgebrachten Material als entscheidendes Kriterium für eine erfolgreiche Anwendung. Zur Verbesserung der Adhäsion wurden die Substratoberflächen laserstrukturiert und der Einfluss mit Adhäsionsversuchen überprüft. T2 - 9. Tagung des DVM-Arbeitskreises Additiv gefertigte Bauteile und Strukturen CY - Stuttgart, Germany DA - 06.11.2024 KW - Kaltgasspritzen KW - Reparatur KW - Ermüdungsfestigkeit KW - Laserstrukturierung KW - Luft- und Raumfahrt PY - 2024 AN - OPUS4-63179 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kruse, Julius T1 - Anwendung der IBESS-Prozedur zur Berechnung der Schwingfestigkeit geschweißter bauteilähnlicher Proben mit künstlichen Defekten N2 - Im Rahmen eines Kooperationsprojekts mit der Schottel GmbH wurde eine bauteilnahe Probengeometrie entwickelt, mit der sich unter Verwendung einer einachsigen Prüfmaschine das Spannungstiefenprofil in dem unter überlagerter Biege- und Zugspannung beanspruchtem Querschnitt im Schweißnahtübergang des Bauteils reproduzieren ließ. Proben dieser Geometrie wurden vom Kooperationspartner im geschweißten bzw. geschweißten und spannungsarmgeglühten Zustand bereitgestellt. An der BAM wurden je Wärmebehandlungszustand mittels Senkerodieren zwei verschiedene künstliche Defektgeometrien im Schweißnahtübergang eingebracht. Anhand der Proben wurden experimentell für alle vier Probenzustände Wöhlerlinien für ein Spannungsverhältnis von R = 0,1 ermittelt. Zusätzlich wurde das u.a. an der BAM entwickelte IBESS-Verfahren angewandt, um die Wöhlerlinien analytisch zu bestimmen. Hierbei wurde eine sehr gute Übereinstimmung von Berechnung und Experiment erreicht, wobei die Berechnung zu einer leicht konservativen Lebensdauervorhersage führte. T2 - 56. DVM Tagung "Bruchmechanik und Bauteilsicherheit" CY - Kassel, Germany DA - 20.02.2024 KW - Bruchmechanik KW - Ermüdung KW - Schwingfestigkeit KW - Schweißverbindungen PY - 2024 AN - OPUS4-59781 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Scacco, F. A1 - Zerbst, Uwe A1 - Meneghetti, G. A1 - Madia, Mauro T1 - Comparison between PSM and IBESS approaches for the fatigue life estimation of weldments N2 - In the framework of the fatigue assessment of welded components, several methods are available in design standards such as the nominal stress, hot-spot stress, notch stress and linear elastic fracture mechanics approaches. The present paper aims at comparing two advanced local approaches for the fatigue strength assessment of different welded joints made of steel. The first one is IBESS which is based on short crack fracture mechanics. The second one is the PSM which instead involves the strain energy density approach. Both methods will be briefly presented, and the fatigue life prediction results discussed. The results obtained for the joint geometries considered in this work show advantages and drawbacks of the approaches, which are thoroughly analysed as well. KW - Fatigue KW - Welded joints KW - FAT class KW - IBESS KW - Peak stress method (PSM) KW - Finite element (FE) PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-545139 DO - https://doi.org/10.1007/s40194-022-01284-7 SP - 1 EP - 23 PB - Springer AN - OPUS4-54513 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Madia, Mauro A1 - Zerbst, Uwe A1 - Werner, Tiago T1 - Estimation of the Kitagawa-Takahashi diagram by cyclic R curve analysis N2 - The Kitagawa-Takahashi (KT) diagram is a proven concept for describing the fatigue limit in presence of a defect or crack. It can be determined empirically with great experimental effort. It can also be estimated by means of the El Haddad relationship if the endurance limit and the long fatigue crack propagation threshold are available in reasonable accuracy. A third option is the determination using the cyclic R-curve, which describes the dependency of the fatigue crack propagation threshold on the crack growth at the short crack propagation stage. This can be experimentally determined using a closure-free initial pre-crack. It can then be applied to the determination of crack arrest for a given applied load and a given defect or crack size. Compared to the other two methods mentioned above, this option has considerable advantages: It can be applied to any component and any stress ratio. It allows the treatment of multiple cracks and provides estimations of the S-N curve in the finite life regime as well as at the endurance limit. Compared to the empirical determination of the KT diagram, the experimental effort is significantly lower and compared to the El Haddad approach it avoids problems such as the use of non-conservative long fatigue crack propagation thresholds (when the conventional load reduction method is applied to materials prone to corrosion) and the mathematical predetermination of the curve shape. The work introduces the method and provides a critical discussion as well as quantitative comparison between the different methods. T2 - FATIGUE DESIGN 2021 CY - Online meeting DA - 17.11.2021 KW - Fatigue life KW - Endurance limit KW - Kitagawa-Takahashi diagram KW - Cyclic R-curve PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-544931 DO - https://doi.org/10.1016/j.prostr.2022.03.032 SN - 2452-3216 VL - 38 SP - 309 EP - 316 PB - Elsevier B.V. AN - OPUS4-54493 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schönherr, J. A. A1 - Duarte, Larissa A1 - Madia, Mauro A1 - Zerbst, Uwe A1 - Geilen, M. B. A1 - Klein, M. A1 - Oechsner, M. T1 - Robust determination of fatigue crack propagation thresholds from crack growth data N2 - The robust determination of the threshold against fatigue crack propagation DKth is of paramount importance in fracture mechanics based fatigue assessment procedures. The standards ASTM E647 and ISO 12108 introduce operational definitions of DKth based on the crack propagation rate da/dN and suggest linear fits of logarithmic DK– da/dN test data to calculate DKth. Since these fits typically suffer from a poor representation of the actual curvature of the crack propagation curve, a method for evaluating DKth using a nonlinear function is proposed. It is shown that the proposed method reduces the artificial conservativeness induced by the evaluation method as well as the susceptibility to scatter in test data and the influence of test data density. KW - Fatigue crack propagation threshold KW - ISO 12108 KW - ASTM E647 KW - Data evaluation methods KW - Experimental determination PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-552153 DO - https://doi.org/10.3390/ma15144737 SN - 1996-1944 VL - 15 IS - 14 SP - 1 EP - 21 PB - MDPI CY - Basel AN - OPUS4-55215 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Analytische Prozedur zur Berechnung der Ermüdungslebensdauer basierend auf effektiven Rissfortschrittsdaten und zyklischer R-Kurve N2 - Bruchmechanik-basierende Methoden können für die Ermüdungsbewertung von mechanischen Bauteilen angewendet werden, die Defekte oder Risse enthalten und zyklischen Belastungen ausgesetzt sind. Die Kenntnis des Risswachstumsverhaltens für kurze und lange Risse ermöglicht die Bestimmung sowohl endlicher als auch unendlicher Lebensdauer. Ein erstes Problem ergibt sich jedoch aus der empirischen Bestimmung von Ermüdungswerkstoffkennwerten, die je nach Prüfbedingungen, z. B. Prüfmethode, Frequenz und Spannungsverhältnis R, variieren. Dies ist auf die Rissschließeffekte und weitere Umgebungsphänomene zurückzuführen, die das Rissfortschrittsverhalten beeinflussen. Ein zweites Problem ist das Fehlen von Standardversuchsverfahren zur Bestimmung des Schwellenwerts gegen Ermüdungsrissausbreitung ΔKth in Abhängigkeit von der Rissausbreitung. Dies ist problematisch, da ΔKth mit der Zunahme der Rissschließeffekte im Kurzrissbereich zunimmt und seine ungenaue experimentelle Bestimmung zu großen Abweichungen bei der Bewertung und, was noch kritischer ist, zu nicht konservativen Vorhersagen führt. Mit dem Ziel, zuverlässigere und sicherere Bewertungsverfahren bereitzustellen, wird in dieser Arbeit eine Methode vorgeschlagen, die auf effektiven Risswachstumsdaten basiert, die bei hohen Spannungsverhältnissen (R ≈ 0,8) ermittelt wurden. Zur Beschreibung der Entwicklung der Rissschließeffekte wird ein Kurzrissmodell auf der Grundlage von zyklischen R-Kurven und CPLR-Daten verwendet. Die analytischen Vorhersagen werden mit experimentellen Daten verglichen, die zur Validierung des Verfahrens durchgeführt wurden, und die daraus entstandenen Unterschiede werden diskutiert. Übersetzt mit DeepL.com (kostenlose Version) T2 - BMDK-Seminar SS24 CY - Magdeburg, Germany DA - 10.04.2024 KW - Schwellenwert gegen Ermüdungsrissausbreitung KW - Rissschließeffekte KW - Ermüdungslebensdauer KW - Zyklische R-Kurve PY - 2024 AN - OPUS4-59876 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Duarte, Larissa A1 - Madia, Mauro A1 - Zerbst, Uwe T1 - The effect of the environmental conditions on the threshold against fatigue crack propagation N2 - The threshold against fatigue crack propagation (ΔKth) is a crucial parameter for the damage tolerance assessment of engineering components subjected to cyclic loading and it is composed by two distinct components, one intrinsic, dependent on the elastic material properties and the lattice type, and one extrinsic, related to the occurrence of crack closure effects. An important issue is that several factors can influence ΔKth and, in general, the fatigue crack propagation behavior. In this work, the influence of the experimental procedure, air humidity, stress ratio and test frequency on da/dN-ΔK data has been investigated. Results are discussed with their potential causes and consequences on the calculations of the residual lifetime. KW - Fatigue crack propagation threshold KW - Crack closure effect KW - Experimental procedure KW - Environmental conditions PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-544905 DO - https://doi.org/10.1016/j.prostr.2022.03.030 VL - 38 SP - 292 EP - 299 PB - Elsevier B.V. AN - OPUS4-54490 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Determination of the Kitagawa-Takahashi diagram for the EA4T railway axle steel by means of the cyclic R-curve method N2 - The Kitagawa-Takahashi (KT) diagram is a well-established tool in the fatigue community for the prediction of the fatigue limit of metallic materials in presence of defects. Nevertheless, its determination is associated with a large number of fatigue tests carried out on specimens with artificial defects (notches) to describe the fatigue limit-defect size relationship in the short crack regime. The preparation of the specimens and the execution of the tests is time expensive. Therefore, few phenomenological models have been introduced in the past to provide a first approximation of the KT diagram based solely on the fatigue limit for smooth specimen and the fatigue crack propagation threshold for long cracks. Despite the use of such models is widely spread, these suffer from problems related to the uncertainties of the material parameters. Furthermore, the mechanics of short cracks, which is the physical mechanism behind the concept of the fatigue limit, is not considered. This work discusses the advantages and drawbacks of using short fatigue crack propagation models for predicting the fatigue limit of flawed metallic materials. The KT diagrams for a EA4T railway axle steel in as-received and full-hardened condition are approximated by means of the cyclic R-curve method. T2 - 13th International Fatigue Congress CY - Hiroshima, Japan DA - 06.11.2023 KW - Fatigue limit KW - Crack propagation KW - Short crack KW - Cyclic R-curve KW - EA4T railway axle steel PY - 2023 AN - OPUS4-58867 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa T1 - Fatigue assessment procedure based on effective crack propagation data and cyclic R-curve N2 - Fracture mechanics-based methods can be applied to the fatigue assessment of mechanical components containing defects or cracks subjected to cyclic loading. The knowledge of the crack growth behavior for short and long cracks enables the determination of both finite and infinite life regimes. Nevertheless, a first problem arises from the empirical determination of the fatigue data, which vary according to the test conditions, e.g., the test method, frequency and the stress ratio R. This is due to crack closure and further environmental phenomena affecting crack propagation behavior. A second issue regards the lack of standard experimental procedures for the determination of the fatigue crack propagation threshold ΔKth dependency on the crack size. This is problematic, since ΔKth increases with the build-up of the closure effects in the short crack regime and its inaccurate experimental determination leads to large deviations in the assessment and, even more critical, to non-conservative predictions. Aiming at providing more reliable and safer assessment procedures, the present work proposes a method based on effective crack growth data obtained at high stress ratios (R ≈ 0.8). A short-crack model based on the cyclic R-curve and CPLR data is employed for describing the development of the closure effects. The predictions are compared to established methods and validated by experimental tests. T2 - Fatigue 2022+1 CY - Hiroshima, Japan DA - 06.11.2023 KW - Component assessment KW - Fatigue crack propagation KW - Fatigue threshold KW - Crack closure KW - Cyclic R-curve PY - 2023 AN - OPUS4-58842 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa A1 - Zerbst, Uwe A1 - Madia, Mauro T1 - Vergleichende Untersuchungen zum intrinsischen Schwellenwert der da/dN-ΔK-Kurve N2 - Für die Bestimmung der Restlebensdauer zyklisch beanspruchter Bauteile kommt dem Schwellenwert für Ermüdungsrissausbreitung, Δ𝐾𝑡ℎ, und dem sich anschließenden Schwellenwertbereich der 𝑑𝑎𝑑𝑁⁄−Δ𝐾-Kurve große Bedeutung zu. Dem stehen Unsicherheiten bei der Bestimmung und Analyse gegenüber. Der Aufsatz befasst sich mit der Ermittlung des sogenannten intrinsischen Schwellenwerts, der als robuster Eingangsparameter für eine „rissschließfreie“ Analyse der Restlebensdauer von entscheidender Bedeutung ist. T2 - 53. Tagung des DVM-Arbeitskreises Bruchmechanik und Bauteilsicherheit CY - Online meeting DA - 18.02.2021 KW - Schadenstolerante Bauteilauslegung, Restlebensdauer, intrinsischer Schwellenwert gegen Ermüdungsrissausbreitung PY - 2021 SN - 2366-4797 SP - 211 EP - 220 PB - Deutscher Verband für Materialforschung und -prüfung e.V. (DVM) CY - Berlin AN - OPUS4-52704 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Duarte, Larissa A1 - Zerbst, Uwe A1 - Madia, Mauro T1 - Der Schwellenwert der da/dN-∆K-Kurve als Auslegungskriterium für die Bauteilbewertung N2 - Für die Bestimmung der Restlebensdauer zyklisch beanspruchter Bauteile kommt dem Schwellenwert für Ermüdungsrissausbreitung ∆Kth und dem sich anschließenden Schwellenwertbereich der da/dN-∆K-Kurve große Bedeutung zu. Dem stehen Unsicherheiten bei der Bestimmung und Analyse gegenüber. Der Aufsatz befasst sich mit der Ermittlung des sogenannten intrinsischen Schwellenwerts, der als robuster Eingangsparameter für eine „rissschließfreie“ Analyse der Restlebensdauer von entscheidender Bedeutung ist. T2 - Tagung Werkstoffprüfung 2020 CY - Online meeting DA - 03.12.2020 KW - Schadenstolerante Bauteilauslegung, KW - Intrinsischer Schwellenwert gegen Ermüdungsrissausbreitung KW - Restlebensdauer PY - 2020 DO - https://doi.org/10.48447/WP-2020-025 SP - 1 EP - 8 AN - OPUS4-52788 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Vecchiato, L. A1 - Madia, Mauro A1 - Meneghetti, G. T1 - Extension of the peak stress method to estimate the fatigue limit of welded joints by means of the cyclic R-curve method N2 - A new simplified and effective method has been formalised to estimate the Constant Amplitude Fatigue Limit (CAFL) of stress-relieved steel welded joints subjected to uniaxial push–pull loading and failing from the weld toe. Starting from the sharp V-notch assumption of the NSIF approach and the cyclic R-curve of the material in the heat affected zone, the proposed method identifies the CAFL as threshold level of the local stress field at the V-notched weld toe in the uncracked configuration. Such threshold stress field assures the crack arrest at the V-notched weld toe, according to the cyclic R-curve analysis. The method has been validated against experimental results and proved effective for a straightforward assessment of the CAFL of welded joints, as the stable crack propagation analysis of classical fracture mechanics approaches can be avoided. KW - Cyclic R-curve KW - Welded joint KW - Fatigue limit KW - Peak stress method KW - Finite element analysis PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-581059 DO - https://doi.org/10.1016/j.tafmec.2023.104039 SN - 0167-8442 VL - 127 SP - 1 EP - 19 PB - Elsevier AN - OPUS4-58105 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zhu, Jiangchao A1 - Madia, Mauro A1 - Schurig, Michael A1 - Kruse, Julius A1 - Conrad, Fabian A1 - Schlums, Hartmut A1 - Kontermann, Christian A1 - Zerbst, Uwe T1 - On the use of representative specimens for the structural integrity assessment of safety-relevant rotating components N2 - Safety-relevant components, for which a failure in service could have catastrophic consequences, are usually designed for extremely low probability of failure and they are subjected to stringent part qualification procedures according to guidelines set by regulatory agencies. Manufacturers are often forced to perform tests on full scale or scaled components to ensure the structural integrity under defined loading conditions, which usually implies a huge experimental and financial effort. Therefore, companies try to develop new strategies such as digital twins, which allow to massively reduce costs, without compromising safety. This work presents a new quasi-static testing and assessment concept, the main idea of which is to replace, or at least reduce, the experimental testing on components by testing specimens representative of the component. Fracture mechanics specimens have been designed iteratively by numerical simulations to match the stress state at the crack-tip of the maximum permissible defect defined by regulatory agencies for the component. Potentially, the major benefit of the proposed approach is that the tests can be performed on conventional laboratory testing machines. The effectiveness of the methodology is demonstrated in case of the structural integrity assessment of a Ni-base superalloy aero-engine turbine disk at overspeed conditions. KW - Structural integrity KW - Turbine disk KW - Burst KW - Fracture mechanics KW - Representative specimens KW - Quasi-static testing PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-624208 DO - https://doi.org/10.1016/j.engfracmech.2024.110710 SN - 0013-7944 VL - 314 SP - 1 EP - 23 PB - Elsevier Ltd. AN - OPUS4-62420 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Werner, Tiago T1 - Damage tolerant design of metallic AM parts N2 - Additive Manufacturing (AM) opens new possibilities in the design of metallic components, including very complex geometries (e.g. structures optimized for certain loads), optimization of materials (e.g. gradient materials) and cost-effective manufacturing of spare parts. In the recent years, it has been used for the first safety-relevant parts, but the consideration of cyclic mechanical behavior in AM is still at the very beginning. The reason for this is the complexity of mechanical material properties, i.e. inhomogeneity, anisotropy and a large number of defects frequently textured and characterized by large scattering in size. Additionally, high surface roughness and residual stresses with complex distributions are typical of AM. Due to these reasons, the transferability of experimentally determined properties from specimens to components is a challenge. This presentation provides an overview of the questions concerning the application of AM to safety-relevant components. Possible strategies for the fatigue design of such components are presented. Besides the Kitagawa-Takahashi-diagram method and the cyclic R-curve analysis as approaches for damage-tolerant design, the identification of critical locations, the problem of representative material properties and the handling of residual stresses are addressed. T2 - 4th international symposium on Fatigue Design and Material Defects CY - Online meeting DA - 26.05.2020 KW - Additive Manufacturing KW - Cyclic R-Curve KW - Component assessment PY - 2020 AN - OPUS4-50938 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Madia, Mauro T1 - Influence of defects on the fatigue strength of parts repaired by cold spray N2 - Cold spray repair is a promising and cost-saving alternative to replacing worn parts. Depositing of materials into machined damage volumes in decent quality can restore the performance of refurbished parts and extend their working life. Furthermore, repair counts as resource-efficient and green process in a world targeting at decarbonization of many industrial sectors. Despite the advantages, cold spray repair still suffers from major limitations which prevent its application in safety relevant parts. The main factors influencing the structural integrity concern the adhesion strength, inherent non-bonded internal interfaces, the reduced ductility by work hardening during the manufacturing process, and the presence of residual stresses. This work presents the results of the collaborative project CORE devoted to the development of automatized repair of aerospace parts by cold spray. The investigations considered the aluminum alloy Al6061-T6 which combines medium-high strength, good workability, and high corrosion resistance. Quasi-static tensile tests, high cycle fatigue and fatigue crack propagation tests were performed to compare the performance of base and repaired materials. These were complemented by fractographic and microstructural investigations. T2 - 5th International Symposium on Fatigue Design and Material Defects CY - Trento, Italy DA - 14.05.2025 KW - Cold Spray KW - Component Repair KW - Fatigue Strength KW - Defects KW - Surface Treatment PY - 2025 AN - OPUS4-63146 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Werner, Tiago A1 - Teske, Tanita A1 - Hilgenberg, Kai A1 - Mauro, Madia A1 - Nielsen, S. A1 - Gärtner, F. A1 - Klassen, T. T1 - Untersuchung des Potenzials von Kaltgasspritzen für die Reparatur zyklisch belasteter Bauteile T1 - Investigation on the capability of cold-spray for repair of cyclically loaded components N2 - Die Reparatur mittels Kaltgasspritzen ist eine vielversprechende Alternative zum teuren Austausch fehlerbehafteter Bauteile in der Luft- und Raumfahrt. Im Rahmen dieser Arbeit wurde das Potential des Verfahrens an der hochfesten Aluminiumlegierungen Al6061-T6 unter Anwendung von Stickstoff als kostengünstiges Prozessgas untersucht. Es wurden quasi-statische Zugversuche und einachsige Zeitfestigkeitsversuche mit besonderem Fokus auf das in-situ Kugelstrahlen zur Verbesserung der mechanischen Eigenschaften durchgeführt. Im Ergebnis wurde die Verbesserung der Adhäsion zwischen Substrat und aufgebautem Werkstoff als entscheidendes Kriterium für eine Anwendbarkeit ermittelt. Die Laserstrukturierung von Substratoberflächen ist hierfür vielversprechend und wurde im Rahmen der Arbeit mittels Adhäsionsversuchen untersucht. N2 - Repair by cold-spray is a promising alternative to the costly replacement of flawed components in aerospace applications. In the present work this process was investigated on the high-strength aluminum alloy Al6061-T6. For the cold-spray process, inexpensive Nitrogen was used as process-gas. Quasi-static tensile and highcycle- fatigue tests (HCF) were performed, focusing on in-situ shot peening to improve the mechanical properties of the repaired part. An improved adhesion between substrate and built-up material was identified as a key-factor for the applicability of the process. Under this respect laser-structuring of the substrate surface was applied and its effect on the mechanical performance of the restored samples were examined by adhesion tests. T2 - 9. Tagung des DVM-Arbeitskreises Additiv gefertigte Bauteile und Strukturen CY - Stuttgart, Germany DA - 06.11.2024 KW - Kaltgasspritzen KW - cold-spray KW - Reparatur KW - Repair KW - Ermüdungsfestigkeit KW - Fatigue KW - Luft- und Raumfahrt KW - Aerospace KW - Substratvorbehandlung KW - Substrate pre-treatment PY - 2024 DO - https://doi.org/10.48447/ADD-2024-BB VL - 409 SP - 67 EP - 79 AN - OPUS4-63182 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -