TY - CONF A1 - Roveda, Ilaria A1 - Serrano Munoz, Itziar A1 - Madia, Mauro T1 - Investigation of residual stresses and microstructure effects on the fatigue behaviour of a L-PBF AlSi10Mg alloy N2 - Laser Powder Bed Fusion (L-PBF) allow the fabrication of lightweight near net shape AlSi10Mg components attractive to the aerospace, automotive, biomedical and military industries. During the build-up process, high cooling rates occur. Thus, L-PBF AlSi10Mg alloys exhibit a Si-nanostructure in the as-built condition, which leads to superior mechanical properties compared to conventional cast materials. At the same time, such high thermal gradients generally involve a deleterious residual stress (RS) state that needs to be assessed during the design process, before placing a component in service. To this purpose post-process heat treatments are commonly performed to relieve detrimental RS. In this contribution two low-temperature stress-relief heat treatments (SRHT) are studied and compared with the as-built state: a SRHT at 265°C for 1 hour and a SRHT at 300°C for 2 hours. At these temperatures microstructural changes occur. In the as-built state, Si atoms are supersaturated in the α-aluminium matrix, which is enveloped by a eutectic Si-network. At 265°C the Si precipitation from the matrix to the pre-existing network is triggered. Thereafter, above 295°C the fragmentation and spheroidization of the Si branches takes place, presumably by Al–Si interdiffusion. After 2 hours the original eutectic network is completely replaced by uniformly distributed blocky particles. The effect of the heat and the microstructure modification on the RS state and the fatigue properties is investigated. Energy dispersive x-ray and neutron diffraction are combined to investigate the near-surface and bulk RS state of a L-PBF AlSi10Mg material. Differences in the endurance limit are evaluated experimentally by high cycle fatigue (HCF) tests and cyclic R-curve determination. T2 - 43rd Materials Mechanics Seminar CY - Sani, Chalkidiki, Greece DA - 05.06.2022 KW - AlSi10Mg KW - Fatigue KW - Neutron diffraction KW - X-ray diffraction PY - 2022 AN - OPUS4-55090 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Han, Ying A1 - Kruse, Julius A1 - Madia, Mauro A1 - Radners, Jan A1 - von Hartrott, Philipp A1 - Skrotzki, Birgit T1 - The influence of aging and mean stress on fatigue of Al-alloy EN AW-2618A N2 - In this study, the influence of aging and mean stress on fatigue of the aluminium-alloy EN AW-2618A is investigated. Therefore axial fatigue tests are carried out on smooth specimens. The experiments show that the fatigue life decreases with increasing mean stress. Furthermore, the tests with the overaged specimens demonstrate that the number of cycles to failure is decreasing with increasing aging time. T2 - LCF9 CY - Berlin, Germany DA - 21.06.2022 KW - Fatigue KW - Aluminium alloy KW - EN AW-2618A KW - Damage Behavior PY - 2022 AN - OPUS4-55125 LA - eng 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 JF - Welding in the World 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 - THES A1 - Nielow, Dustin T1 - Einfluss fertigungsbedingter Imperfektionen auf die Schwingfestigkeit von FKV-Schalenstrukturen in Sandwichbauweise T2 - BAM-Dissertationsreihe N2 - Rotorblätter von Windenergieanlagen (WEA) weisen häufig nach wenigen Jahren, lange vor dem Erreichen der prognostizierten Lebensdauer von 20 bis 30 Jahren Risse in der Blattschale auf. Die Folge sind aufwendige Reparaturen am installierten und schwer zugänglichen Rotorblatt und der kostenintensive Nutzungsausfall durch den Stillstand der WEA. Als mögliche Initiatoren für die Schäden in der Blattschale der Rotorblätter gelten fertigungsbedingte Imperfektionen. Für die Untersuchung des Einflusses dieser Imperfektionen auf das Ermüdungsverhalten der Rotorblätter wurde an der BAM (Bundesanstalt für Mate-rialforschung und -prüfung) ein Prüfstand für statische und zyklische Versuche von Schalensegmenten im intermediate scale entwickelt und betrieben. Die untersuchten Schalensegmente in Sandwichbauweise sind der Rotorblattschale von WEA im Hinblick auf die Strukturmechanik, die eingesetzten Halbzeuge, den Laminataufbau und dem eingesetzten Fertigungsverfahren ähnlich. Als Imperfektionen wurden verschiedenen Variationen von Lagenstößen in die Hautlagen und Schaumstöße mit Breitenvariation in den Stützkern reproduzierbar eingebracht. Die Überwachung des Schädigungszustandes während der Schwingversuche unter realistischen Lastszenarien erfolgt über eine kombinierte in situ Schädigungsüberwachung mittels passiver Thermografie und Felddehnungsmessung. Mit den durchgeführten Schwingversuchen und der begleitenden Überwachung des Schädigungszustandes ließen sich die Schadensinitiation und die signifikante Herabsetzung der Lebensdauer durch die eingebrachten Imperfektionen zweifelsfrei nachweisen und entsprechende Konstruktionshinweise für die betriebssichere Auslegung von Sandwichstrukturen ableiten. N2 - Wind turbines often exhibit cracks in the blade shells after only a few years in service, significantly before their expected 20 to 30 year design lifespan. This leads to complicated repairs on difficult to reach rotor blades, and can cause a cost-intensive standstill of the turbine. A possible source of these defects in the rotor blade shells are the imperfections which occur during production. In order to investigate the effect of these imperfections on the fatigue behavior of rotor blades, a test rig was developed at the BAM (Bundesanstalt für Materialforschung und -prüfung) upon which intermediate scale static and cyclic-fatigue testing could be performed. The complementary sandwich shell specimens developed and investigated with the test rig are representative of the outer shell of wind turbine rotor blades in terms of materials and manufacturing processes, as well as structural mechanics. The specimens were built with reproducible imperfections, including laminate overlaps in the face sheets and gaps of varying size in the foam core. The damage condition was monitored during cyclic-fatigue testing under realistic load cases using a combination of in-situ passive thermography and strain field measurement. The cyclic testing and parallel non-destructive structural health monitoring of the shell specimens showed the imperfections to significantly influence the damage initiation and decrease the component service life. The results can be used accordingly as recommendations for operationally more reliable design of sandwich structures. T3 - BAM Dissertationsreihe - 170 KW - Erneuerbare Energien KW - Windenergie KW - Verbundwerkstoffe KW - Betriebsfestigkeit KW - Komponentenprüfung KW - Renewable ernergy KW - Wind energy KW - Intermediate scale KW - Composites KW - Fatigue PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-546701 SN - 1613-4249 VL - 170 SP - 1 EP - 178 PB - Bundesanstalt für Materialforschung und -prüfung (BAM) CY - Berlin AN - OPUS4-54670 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Werner, Tiago A1 - Madia, Mauro A1 - Zerbst, Uwe T1 - Comparison of the fatigue behavior of wrought and additively manufactured AISI 316L JF - Procedia Structural Integrity N2 - Additive manufacturing (AM) is becoming increasingly important in engineering applications due to the possibility of producing components with a high geometrical complexity allowing for optimized forms with respect to the in-service functionality. Despite the promising potential, AM components are still far from being used in safety-relevant applications, mainly due to a lack of understanding of the feedstock-process-properties-performance relationship. This work aims at providing a full characterization of the fatigue behavior of the additively manufactured AISI 316L austenitic stainless steel and a direct comparison with the fatigue performance of the wrought steel. To this purpose, a set of specimens has been produced by laser powder bed fusion (L-PBF) and subsequently heat treated at 900 °C for 1 hour for complete stress relief, whereas a second set of specimens has been machined out of hot-rolled plates. Low cycle fatigue (LCF) and high cycle fatigue (HCF) tests have been conducted for characterizing the fatigue behavior. The L-PBF material had a higher fatigue limit and better finite life performance compared to wrought material. Both, LCF and HCF-testing revealed an extensive cyclic softening. T2 - FATIGUE DESIGN 2021 CY - Online meeting DA - 17.11.2021 KW - Additive manufacturing KW - L-PBF KW - 316L KW - Fatigue KW - LCF KW - HCF PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-544952 DO - https://doi.org/10.1016/j.prostr.2022.03.056 SN - 2452-3216 VL - 38 SP - 554 EP - 563 PB - Elsevier B.V. AN - OPUS4-54495 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Baer, Wolfram T1 - Detection and understanding of the chunky graphite degeneration in ferritic spheroidal graphite cast iron materials with respect to fatigue N2 - CHG is very different compared to other graphite degenerations or defects; Filigree, multi-branched string-like, 3d interconnected structure; Morphology and volumetric amount of CHG cannot be accessed by stereological interpretation of 2d section data; Field-tested, technically established method to quantify CHG in components not available; Fatigue: CHG causes substantial reduction in fatigue limit and significant increase in crack growth rate; Therefore: Avoid or exclude CHG! T2 - 4th International Symposium on Fatigue Design and Material Defects CY - Online meeting DA - 26.05.2020 KW - Ductile cast iron KW - Chunky graphite degeneration KW - Fatigue KW - Correlation microstructure to properties PY - 2020 AN - OPUS4-54409 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - THES A1 - Kraus, David T1 - Ermüdungsverhalten von Glasfaser-Kunststoff-Verbunden unter thermomechanischer Beanspruchung T2 - BAM-Dissertationsreihe N2 - Die Werkstoffgruppe der Faser-Kunststoff-Verbunde (FKV) hat sich aufgrund ihrer hervorragenden Leichtbaueigenschaften unter anderem im Sportgerätebau, in der Luft- und Raumfahrt und in der Windenergieindustrie etabliert. Die so hergestellten Strukturen sind in der Regel nicht nur mechanischen Belastungen, sondern auch thermischen Lasten in einem breiten Temperaturspektrum ausgesetzt. Dennoch ist die Auswirkung des Temperatureinflusses bei einer Kombination von thermischer und mechanischer Last auf die Lebensdauer von Strukturen aus FKV bisher nur wenig untersucht. Im Rahmen dieser Arbeit wird der Einfluss von Temperaturen zwischen 213 K und 343 K auf einen Glasfaser-Epoxidharz-Verbund experimentell untersucht. Das Material wird in diesem Temperaturbereich eingehend charakterisiert: Es werden sowohl die thermomechanischen Eigenschaften von Faser- und Matrixwerkstoff als auch die des Verbundes ermittelt. In einem weiteren Schritt wird dann der Einfluss der Temperatur auf die Schädigungsentwicklung im quasi-statischen Lastfall sowie unter schwingender Ermüdungsbeanspruchung bei verschiedenen FKV-Mehrschichtverbunden analysiert. Basierend auf den experimentellen Daten wird ein Zusammenhang zwischen der Schädigung und der Anstrengung der Matrix innerhalb der Einzelschicht demonstriert. Die Matrixanstrengung wird mithilfe eines mikromechanischen Modells unter Berücksichtigung der thermomechanischen Eigenspannungen analytisch berechnet. Bei Querzugbeanspruchung kann gezeigt werden, dass eine Vorhersage der Schädigung in Abhängigkeit der Volumenänderungsenergie innerhalb der Matrix getroffen werden kann. Mithilfe des Konzepts der Matrixanstrengung ist eine Vorhersage der Lebensdauer des Werkstoffs unter schwingender Ermüdungsbeanspruchung in Abhängigkeit der Einsatztemperatur möglich. N2 - Due to their superior lightweight properties, fiber reinforced polymer (FRP) materials are well established in various fields, such as sports equipment, aerospace or wind energy structures. These structures are not only subjected to mechanical loads, but also to a broad spectrum of thermal environments. However, the impact of temperature on the fatigue life of thermomechanically loaded FRP structures is barely investigated to-date. In the scope of this work, the influence of temperatures in a range of 213 K to 343 K on a glass fiber reinforced epoxy polymer is experimentally examined. An extensive thermo-mechanical characterization of the static properties of the material is performed. The neat resin and Fiber material are investigated, as well as the composite. In addition, the impact of thermal loads on the damage evolution under quasi-static as well as cyclic fatigue loading is investigated for different multi-angle laminates. Based on the experimental data, a correlation is shown between damage and matrix effort of the unidirectional layer. The matrix effort is calculated according to a micromechanical model considering thermal residual stresses. Particularly under transverse loading, the damage Evolution can be predicted as a function of the dilatational strain energy of the matrix. Using the concept of the matrix effort presented in this work, a prediction of the fatigue life of the investigated material at different ambient temperature conditions can be performed. T3 - BAM Dissertationsreihe - 169 KW - Ermüdung KW - Faser-Kunststoff-Verbund KW - GFK KW - Schädigung KW - Thermomechanik KW - Fatigue KW - Composite KW - Glas fibre reinforced polymer KW - Damage KW - Thermomechanics PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-530253 SN - 1613-4249 VL - 169 SP - 1 EP - 164 PB - Bundesanstalt für Materialforschung und -prüfung (BAM) CY - Berlin AN - OPUS4-53025 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bruno, Giovanni T1 - Assessing the safety of new technologies: Summary of Project AGIL N2 - In Additive Manufacturing everybody is talking about Free Form, Unconventional Design, Re-thinking Components, “Think out of the box”. However, there are a few outstanding question: a) What are the material properties ? They certainly differ from literature values for conventional materials; b) How about the microstructure? It is different from conventional materials. Does it stay so with ageing? How does it form? c) Do we properly take residual stress into account? We often blame them for our ignorance about failure scenarios. d) Do we apply tailored heat treatments? Very often, we follow conventional schedules… This talk describes the summary of the efforts carried out within the BAM Project AGIL. At BAM, we aimed to thoroughly investigate the microstructure and how it evolves as a function of load and temperature (service), to determine the material properties after different process and service conditions, to properly determine residual stress and the way it impacts mechanical properties and component performance, to properly quantify the impact of (unavoidable?) defects, and to determine heat treatments tailored to the process-specific material (stress relieve, microstructure homogenization etc.). The Project AGIL was and is intimately coupled with the project ProMoAM, dealing with online monitoring of AM processes. T2 - Workshop In-situ Monitoring and Microstructure Development in Additive Manufactured Alloys CY - Online meeting DA - 19.04.2021 KW - Mechanical properties KW - Additive manufacturing KW - Residual Stress KW - Microstructure KW - Fatigue KW - Creep PY - 2021 AN - OPUS4-52581 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zerbst, Uwe A1 - Madia, Mauro A1 - Bruno, Giovanni A1 - Hilgenberg, Kai T1 - Towards a Methodology for Component Design of Metallic AM Parts Subjected to Cyclic Loading JF - Metals N2 - The safe fatigue design of metallic components fabricated by additive manufacturing (AM) is still a largely unsolved problem. This is primarily due to (a) a significant inhomogeneity of the material properties across the component; (b) defects such as porosity and lack of fusion as well as pronounced surface roughness of the asuilt components; and (c) residual stresses, which are very often present in the as‐built parts and need to be removed by post‐fabrication treatments. Such morphological and microstructural features are very different than in conventionally manufactured parts and play a much bigger role in determining the fatigue life. The above problems require specific solutions with respect to the identification of the critical (failure) sites in AM fabricated components. Moreover, the generation of representative test specimens characterized by similar temperature cycles needs to be guaranteed if one wants to reproducibly identify the critical sites and establish fatigue assessment methods taking into account the effect of defects on crack initiation and early propagation. The latter requires fracture mechanics‐based approaches which, unlike common methodologies, cover the specific characteristics of so‐called short fatigue cracks. This paper provides a discussion of all these aspects with special focus on components manufactured by laser powder bed fusion (L‐PBF). It shows how to adapt existing solutions, identifies fields where there are still gaps, and discusses proposals for potential improvement of the damage tolerance design of L‐PBF components KW - L‐PBF KW - Fatigue KW - Fracture KW - Defects PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-525822 DO - https://doi.org/10.3390/met11050709 VL - 11 IS - 5 SP - 709 PB - MDPI CY - Basel AN - OPUS4-52582 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Wallau, Wilma A1 - Recknagel, Christoph A1 - Smales, Glen Jacob T1 - Structural silicone sealants after exposure to laboratory test for durability assessment JF - Journal of Applied Polymer Science N2 - During the service life of structural sealant glazing (SSG) facades, the loadbearing capacity of the silicone bonds needs to be guaranteed. Laboratory Tests can assess the durability of SSG-systems based on mechanical characteristics of the bond after simultaneous exposure to both climatic and mechanical loads. This article studies how the material characteristics of two common structural sealants are affected by laboratory and field exposure. Dynamic mechanical Analysis (DMA) confirms a reduction in the dynamic modulus of exposed Silicone samples. Results from thermogravimetric analysis, Fourier-transform infrared spectroscopy, differential scanning calorimetry, and small-angle X-ray scattering/wide-angle X-ray scattering show differences between the two sealants and indicate no/minor changes in the composition and morphology of the laboratory and field exposed sealants. Mechanical characterization methods, such as DMA, and tensile and shear testing of the structural bond, are shown to be sensitive toward the combined climatic and mechanical loadings, and are hence suitable for studying degradation mechanisms of structural sealants. KW - Aging KW - Analytical methods KW - Fatigue KW - Silicone elastomer KW - Structural sealant glazing PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-527217 DO - https://doi.org/10.1002/app.50881 VL - 138 IS - 35 SP - 50881 PB - Wiley AN - OPUS4-52721 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -