TY - JOUR A1 - Schilling, Markus A1 - Böhning, Martin A1 - Oehler, H. A1 - Alig, I. A1 - Niebergall, Ute T1 - Environmental stress cracking of polyethylene high density (PE-HD) induced by liquid media – Validation and verification of the full-notch creep test (FNCT) T1 - Umgebungsinduzierte Spannungsrissbildung von Polyethylen- Werkstoffen hoher Dichte durch flüssige Medien – Validierung und Verifizierung des Kriechversuchs an Probekörpern mit umlaufender Kerbe N2 - The full-notch creep test (FNCT) is widely used to characterize the slow crack growth (SCG) behavior of polyolefin materials in “inert” media as well as effects of environmental stress cracking (ESC) in which the medium has decisive influence on damage mechanism and time to failure. The test is of greatest importance for pipe and blow molding types of polyethylene, high density (PE-HD). Usually the full-notch creep test is applied as a standardized testing method (ISO 16770) using a few universal liquid media, such as solutions of Arkopal N 100. In our study, selected relevant polyethylene, high density materials are investigated also in real media – practical formulations as well as representative pure chemicals – and influences of temperature and geometry of specimen and notch are explicitly addressed. Furthermore, the investigations comprise also the environmental stress cracking behavior of polyethylene, high density in media that are sorbed to a significant extent – examples are diesel and biodiesel – based on comparison with samples previously saturated with those media. Thus, also the underlying diffusion controlled sorption process has to be assessed before. The investigations were performed using a full-notch creep testing device with 12 individual sub-stations, each equipped with individual electronic stress and temperature control and continuous online monitoring of the specimen elongation. N2 - Der Kriechversuch an Probekörpern mit umlaufender Kerbe (FNCT) wird flächendeckend angewendet, um das Verhalten von Polyolefinen sowohl gegenüber langsamen Risswachstums (SCG) bei Kontakt mit „inerten“ Medien als auch gegenüber umgebungsbedingtem Spannungsrisswachstum (ESC), bei welchem das umgebende Medium entscheidenden Einfluss auf den Schädigungsmechanismus und die Standzeit hat, zu charakterisieren. Der Test ist von großer Bedeutung bei der Analyse von hochdichten Polyethylen-Typen, die als Rohr- und Blasformwerkstoffe angewendet werden – dabei besonders für Transport und Verpackung von Gefahrstoffen, aber auch für weitere Hochleistungsanwendungen. Üblicherweise wird der Kriechversuch an Probekörpern mit umlaufender Kerbe als Normmethode (ISO 16770) unter Verwendung einiger weniger universeller Modellflüssigkeiten, wie z. B. Arkopal N 100, durchgeführt. In dieser Studie werden ausgewählte, marktrelevante Polyethylen-Werkstoffe hoher Dichte in realen Medien – praktisch verwendete Gefahrgüter sowie repräsentative reine Chemikalien – untersucht und explizit die Einflüsse von Temperatur und Prüfkörper- sowie Kerbgeometrie adressiert. Weiterhin beinhalten die Untersuchungen die Analyse des umgebungsbedingten Spannungsriss-Verhaltens von Polyethylen hoher Dichte in Medien, die maßgeblich vom Werkstoff sorbiert sind – beispielsweise mit Kraftstoffen wie diesel und biodiesel – basierend auf dem Vergleich mit vorgesättigten Probekörpern. Der dabei vorliegende diffusionsgesteuerte Sorptionsprozess muss dementsprechend zuvor evaluiert werden. Alle Untersuchungen wurden mithilfe einer Kriechversuchsanlage an Probekörpern mit umlaufender Kerbe mit 12 Stationen durchgeführt, welche jeweils mit einer individuell ansteuerbaren elektronischen Spannungs- und Temperatursteuerung sowie fortwährender Online-Überwachung der Prüfkörperdehnung ausgestattet sind. KW - Full-notch creep test (FNCT) KW - Polyethylene (PE-HD) KW - Environmental stress cracking (ESC) KW - Slow crack growth (SCG) KW - Biodiesel PY - 2017 DO - https://doi.org/10.1002/mawe.201700065 SN - 1521-4052 SN - 0933-5137 VL - 48 IS - 9 SP - 846 EP - 854 PB - Wiley-VCH CY - Weinheim AN - OPUS4-41885 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Konnertz, Nora A1 - Ding, Yi A1 - Harrison, W.J. A1 - Budd, P.M. A1 - Schönhals, Andreas A1 - Böhning, Martin T1 - Molecular mobility and gas transport properties of nanocomposites based on PIM-1 and polyhedral oligomeric phenethyl-silsesquioxanes (POSS) N2 - Polymers with intrinsic microporosity (PIMs) are of great interest in the field of gas separation membranes. Already the first synthesized PIM-1 shows extraordinary permeability and selectivity. Unfortunately, PIM-1 is susceptible to physical aging and thus gradually loses its outstanding properties. In this study a polyhedral oligomeric silsesquioxane with phenethyl substituents (PhenethylPOSS) was used as a nanofiller (0–40 wt%) in the PIM-1 matrix to potentially improve the gas transport properties and prevent physical aging. The molecular mobility of the solution-cast nanocomposite films was analyzed by Broadband Dielectric Spectroscopy (BDS). Furthermore, gas permeability was determined with the time lag method (0–20 bar upstream pressure) at 35 °C for N2, O2, CH4 and CO2. KW - Broadband Dielectric Spectroscopy KW - Gas separation KW - Gas permeation KW - Polymers of intrinsic microporosity KW - Nanocomposite KW - POSS KW - PIM-1 PY - 2017 DO - https://doi.org/10.1016/j.memsci.2017.02.007 SN - 0376-7388 SN - 1873-3123 VL - 529 SP - 274 EP - 285 PB - Elsevier B.V. CY - Amsterdam AN - OPUS4-39169 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schilling, Markus A1 - Niebergall, Ute A1 - Böhning, Martin T1 - Full notch creep test (FNCT) of PE-HD – Characterization and differentiation of brittle and ductile fracture behavior during environmental stress cracking (ESC) N2 - The damage mechanisms slow crack growth (SCG) and environmental stress cracking (ESC), relevant for PE-HD materials are characterized based on improved full notch creep testing (FNCT) of two selected typical PE-HD materials for container applications. In this context, a distinction of the failure mechanisms as well as a categorization of involved media is suggested. Employing a novel FNCT device, elongation data were obtained in addition to conventional time-to-failure results of stress-dependent as well as temperature-dependent measurements. Changes in failure behavior, as determined by fracture surface analysis based on light microscopy (LM) and laser scanning microscopy (LSM), are correlated with FNCT results and used to introduce an additional possibility for the identification of brittle/ductile fracture behavior. KW - Environmental stress cracking (ESC) KW - Slow crack growth (SCG) KW - Full notch creep test (FNCT) KW - High-density polyethylene (PE-HD) PY - 2017 DO - https://doi.org/10.1016/j.polymertesting.2017.09.043 SN - 0142-9418 SN - 1873-2348 VL - 64 SP - 156 EP - 166 PB - Elsevier CY - Amsterdam AN - OPUS4-42484 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Bachmann, Marcel A1 - Carstensen, J. A1 - Bergmann, L. A1 - dos Santos, J. F. A1 - Wu, C. S. A1 - Rethmeier, Michael T1 - Numerical simulation of thermally induced residual stresses in friction stir welding of aluminum alloy 2024-T3 at different welding speeds N2 - The paper deals with a numerical finite element simulation of the residual stress evolution in friction stir welding of 6 mm thick aluminum alloy AA2024-T3. The transient thermal field during the welding process was calculated with the commercial code COMSOL Multiphysics 5.0. Therefore, a thermal-pseudo-mechanical (TPM) heat source was implemented. A subsequent mechanical simulation was performed with varying hardening models for different welding speeds of 60 and 300 mm/min. The influence of softening of the material, which was due to hardening precipitation dissolution associated to the heating, was also investigated. Experiments in terms of thermocouple measurements as well as Vickers hardness and X-ray measurements of the residual stresses were conducted and compared to numerically obtained results. A qualitatively as well as quantitatively good agreement was found for different applied welding speeds. KW - Friction stir welding KW - Residual stress KW - Finite element simulation KW - Thermal softening KW - Aluminum alloy 2024-T3 PY - 2017 DO - https://doi.org/10.1007/s00170-016-9793-8 SN - 0268-3768 SN - 1433-3015 VL - 91 SP - 1443 EP - 1452 PB - Springer CY - London AN - OPUS4-40511 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Sproesser, G. A1 - Chang, Y.-J. A1 - Pittner, Andreas A1 - Finkbeiner, M. A1 - Rethmeier, Michael T1 - Energy efficiency and environmental impacts of high power gas metal arc welding N2 - Single-wire gas metal arc welding (SGMAW) and high power tandem GMAW (TGMAW) are evaluated with respect to energy efficiency. The key performance indicator electrical deposition efficiency is applied to reflect the energy efficiency of GMAW in different material transfer modes. Additionally, the wall-plug efficiency of the equipment is determined in order to identify the overall energy consumption. The results show that energy efficiency can be increased by 24% and welding time is reduced over 50% by application of the tandem processes. A comparative life cycle assessment of a 30-mm-thick weld is conducted to investigate the influences of the energy efficiency on the environmental impacts. The environmental impacts on the categories global warming potential, acidification potential, eutrophication potential, and photochemical ozone creation potential can be reduced up to 11% using an energy-efficient TGMAW process. KW - Tandem gas metal arc welding KW - Life cycle assessment (LCA) KW - Energy efficiency KW - High power welding PY - 2017 DO - https://doi.org/10.1007/s00170-017-9996-7 SN - 0268-3768 SN - 1433-3015 VL - 91 IS - 9-12 SP - 3503 EP - 3513 PB - Springer CY - London AN - OPUS4-39564 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröpfer, Dirk A1 - Kromm, Arne A1 - Kannengießer, Thomas T1 - Optimization of welding loads with narrow groove and application of modified spray arc process N2 - Current efforts for lightweight design result in a growing application of high-strength fine-grained structural steel in modern constructions, e.g. mobile cranes, with yield strength from 960 MPa. The design of welded structures and welding processes becomes more challenging with increasing material strength and elastic ratios. High residual stresses are able to diminish lifetime, load capacity and component safety and should be avoided. Recent analyses have shown strong influences of heat control and restraint of the weld due to arising reaction stresses, superimposing with local residual welding stresses. Modern inverter technologies allowed the development of numerous modified spray arc processes driven by power source manufacturers, which provide virtually similar features and several benefits, enabling welding of narrower seams with reduced weld volumes and total heat inputs. This research focuses on welding loads due to modified weld seams. The global reaction forces and moments and their superposition with local residual stresses in welded components due to external shrinkage restraints were investigated using a special testing facility and XRD. The restraint intensity, weld seam geometry and welding process were varied for statistical evaluations of resulting welding loads. When welding under restraint, a reduction of the weld seam volume causes significantly lower reaction stress levels. KW - Residual stresses KW - MAG welding KW - Restraint KW - High-strength steels KW - Process parameters PY - 2017 DO - https://doi.org/10.1007/s40194-017-0484-3 SN - 1878-6669 SN - 0043-2288 VL - 61 IS - 6 SP - 1077 EP - 1087 PB - Springer CY - Berlin Heidelberg AN - OPUS4-41071 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Lamiel, C. A1 - Lee, Y. R. A1 - Cho, M. H. A1 - Tuma, Dirk A1 - Shim, J.-J. T1 - Enhanced electrochemical performance of nickel-cobalt-oxide@reduced graphene oxide//activated carbon asymmetric supercapacitors by the addition of a redox-active electrolyte N2 - Supercapacitors are an emerging energy-storage system with a wide range of potential applications. In this study, highly porous nickel-cobalt-oxide@reduced graphene oxide (Ni-Co-O@RGO-s) nanosheets were synthesized as an active material for supercapacitors using a surfactant-assisted microwave irradiation technique. The RGO-modified nanocomposite showed a larger specific area, better conductivity, and lower resistivity than the unmodified nanocomposite because the RGO facilitated faster ion diffusion/transport for improved redox activity. The synergistic effect of Ni-Co-O@RGO-s resulted in a high capacitance of 1903 F/g (at 0.8 A/g) in a mixed KOH/redox active K3Fe(CN)6 electrolyte. The asymmetric Ni-Co-O@RGO-s//AC supercapacitor device yielded a high energy density and power density of 39 Wh/kg and 7500 W/kg, respectively. The porous structure and combination of redox couples from both the electrode and electrolyte provided a highly synergistic effect, which improved the performance of the supercapacitor device. KW - Ni-Co oxide KW - Reduced graphene oxide KW - Nanocomposite KW - Supercapacitor PY - 2017 DO - https://doi.org/10.1016/j.jcis.2017.08.003 SN - 0021-9797 SN - 1095-7103 VL - 507 SP - 300 EP - 309 PB - Elsevier Inc. CY - Amsterdam AN - OPUS4-41284 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mady, A. H. A1 - Baynosa, M. L. A1 - Tuma, Dirk A1 - Shim, J.-J. T1 - Facile microwave-assisted green synthesis of Ag-ZnFe2O4@rGO nanocomposites for efficient removal of organic dyes under UV- and visible-light irradiation N2 - Nanocomposites of Ag-ZnFe2O4@reduced graphene oxide (rGO) were synthesized using a one-pot microwave-assisted self-assembly method. The morphology and structure of the Ag-ZnFe2O4@rGO nanocomposites were characterized. The nanocomposites formed with 15.2 wt% rGO showed excellent adsorption properties and high photocatalytic activity for the degradation of methylene blue (MB), rhodamine B (RhB), and methyl orange (MO). The synergistic interactions between Ag, ZnFe2O4, and rGO decreased the aggregation of the nanoparticles (NPs) and increased the surface area, resulting in better absorption in both UV and visible light. Such a structure was helpful for separating the photoexcited electron-hole pairs and accelerating electron transfer. Electrochemical impedance spectroscopy (EIS) revealed a smaller resistance in the solid-state interface layer and charge transfer on the composite surface than that of the bare ZnFe2O4 NPs and ZnFe2O4@rGO nanocomposite. The Ag-ZnFe2O4@rGO nanocomposite could be recovered easily by a magnet and reused five times with no significant decrease in photocatalytic activity. The as-prepared Ag-ZnFe2O4@rGO nanocomposite catalyst could be applied to the removal of hard-to-degrade waste materials owing to its high efficiency in both UV and visible light and its excellent reusability. KW - nanoparticles KW - microwave synthesis KW - photocatalysis PY - 2017 DO - https://doi.org/10.1016/j.apcatb.2016.10.033 SN - 0926-3373 SN - 1873-3883 VL - 203 SP - 416 EP - 427 PB - Elsevier B. V. CY - Amsterdam AN - OPUS4-37962 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröpfer, Dirk A1 - Kromm, Arne A1 - Kannengießer, Thomas T1 - Engineering approach to assess residual stresses in welded components N2 - Present trends to lightweight design lead to an expanding relevance of high-strength fine-grained structural steels especially in mobile crane constructions. With growing material strength, the challenge for welding fabrication increases, since high loading capacities and safety requirements have to be accomplished. The utilisation of the high strength potential often requires complex constructions associated with high restraint conditions while welding. Increased residual stresses may occur due to superimposing reaction and restraint stresses, which have to be quantified and evaluated to ensure the safety and integrity of high-strength steel constructions. Particularly, the scope of residual stresses has to be taken into account for different effects in the HAZ, notches, weld and base metal. Commonly, conservative assumptions of residual stresses lead to distinct underestimations of the load bearing capacity particularly for welded high-strength steel constructions. This study concludes results of recent works of the researchers regarding the complex interaction among heat control, material and restraint intensity on the residual stress state in welded components. These analyses are extended by further experiments. Based on the obtained major effects, an approach for a welding residual stress assessment regarding component design according to prevailing standards for crane construction, an important application for high-strength steels, is presented. KW - Process parameters KW - Residual stresses KW - MAG welding KW - Restraint KW - High-strength steels PY - 2017 DO - https://doi.org/10.1007/s40194-016-0394-9 SN - 0043-2288 SN - 1878-6669 VL - 91 IS - 1 SP - 91 EP - 106 PB - Springer CY - Berlin, Heidelberg AN - OPUS4-39044 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schaupp, Thomas A1 - Schröpfer, Dirk A1 - Kromm, Arne A1 - Kannengießer, Thomas T1 - Welding residual stresses in 960 MPa grade QT and TMCP high-strength steels N2 - High-strength steels with yield strengths ≥ 690 MPa are becoming increasingly significant for modern steel constructions. Both quenched and tempered (QT) high-strength steels and steels produced by the thermo-mechanically controlled process (TMCP) are currently available. TMCP-steels are usually provided with a typical mill scale. Apart from the manufacturing process these steels differ also in their chemical composition. The influence of these differences are investigated here with focus on the residual stresses formed during TIG welding. Bead on plate welds have shown characteristic residual stress distributions depending on the type of steel as well as on the heat input and preheat temperature. The following work demonstrates that the fluid flow, induced by the elements present in the mill scale, leads to a deeper penetration of the material. This can also lead to increased residual stresses in the surface of the weld and the HAZ. Furthermore, higher heat input and preheat temperature can induce higher tensile residual stresses − which are evident in the present study. KW - Residual stresses KW - High-strength steel KW - Welding KW - Mill scale KW - Phase transformation PY - 2017 DO - https://doi.org/10.1016/j.jmapro.2017.05.006 SN - 1526-6125 VL - 27 SP - 226 EP - 232 PB - ELSEVIER AN - OPUS4-40312 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -