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This third part of the review on defects as root cause of fatigue failure addresses cavities (pores, micro-shrinkages, unmelted regions), defective microstructures and microcracks as material defects and defects due to local damage during manufacturing, service and maintenance such as dents, scratches and localized corrosion. In addition, damage due to contact fatigue and the effect of surface roughness are discussed in the context of fatigue failure. Also addressed is the competition between different kinds of defects in controlling the initiation and early growth of fatigue cracks.
The paper provides an overview on material defects which may serve as fatigue crack initiation sites and can cause final fatigue failure of a component. These comprise nonmetallic inclusions in Steel and aluminum alloys, cavities such as pores, micro-shrinkages and un-welded regions in cast, sinter and additively manufactured alloys, graphite nodules, shrinkages and other items in modular cast iron, regions of defective microstructure, microcracks and secondary notches such as undercuts and surface roughness. Besides their origin, the effect and mechanisms on fatigue crack initiation and propagation are discussed.
The considerations are proceeded and accompanied by a Brief discussion of some Basic aspects such as the stages of crack propagation along their length scale, the overcoming of crack arrest and the question when a secondary notch can be treated as a crack.
Selective Electron Beam Melting (SEBM) is a promising powder bed Additive Manufacturing technique for near-net-shape manufacture of high-value titanium components. However without post-manufacture HIPing the fatigue life of SEBM parts is currently dominated by the presence of porosity. In this study, the size, volume fraction, and spatial distribution of the pores in model samples have been characterised in 3D, using X-ray Computed Tomography, and correlated to the process variables. The average volume fraction of the pores (b0.2%) was measured to be lower than that usually observed in competing processes, such as selective laser melting, but a strong relationship was found with the differentbeamstrategies used to contour ,and infill by hatching, a part section. The majority of pores were found to be small spherical gas pores, concentrated in the infill hatched region; this was attributed to the lower energy density and less focused beam used in the infill strategy allowing less opportunity for gas bubbles to escape the melt pool. Overall, increasing the energy density or focus of the beam was found to correlate strongly to a reduction in the level of gas porosity. Rarer irregular shaped pores were mostly located in the contour region and have been attributed to a lack of fusion between powder particles.
Laser Plasma Hybrid Welding of Austenitic Stainless Steels - Phenomena of Process Instability
(2007)
Laser plasma hybrid welding has been proved to be a very stable hybrid welding process and
welds of high quality can be produced, especially if high surface quality and low spattering is
demanded such as in welding fabrication of high alloyed austenitic stainless steels.
In particular cases, even though welds display high outer quality, X-ray examinations
revealed weld defects which may range from low porosity to blowhole-like cavities. The
phenomena and the main influencing parameters such as arc current, welding speed and
focal point position are discussed. Parameter fields will be suggested for welding plates of
different austenitic stainless steel grades with thicknesses ranging from 3 to 8 mm. The
results are based on welding experiments carried out using a 4.4 kW diode pumped Nd:YAGlaser.
Thus, also the influence of the feeding fibre diameter has been investigated and it was found
that the resulting beam shape has a major effect on the welding performance.
Ever larger high pressure die castings (HPDC) with ever thinner walls raise the issue of castings defects. Properties of components are often strongly influenced by inner porosity. In the case of high pressure die castings, shrinkage and gas porosity occur. Two possibilities of characterizing porosity – by microscopy and active thermography – are dealt with in two articles. In this article, the microscopic investigations are presented. In a second article, first the feasibility of thermographic detection will be discussed based on simulations and, thereafter, the experimental determination of porosity with active thermography will be described.
IIW-2326
Austenitic and austenitic-ferritic CrMnNi-stainless steels are suitable materials in the transport and automotive industry due to their high corrosion resistance and high strength that allows weight and cost savings. This study focuses on the laser weldability of a commercial lean duplex and an austenitic high manganese stainless steel. The impact of different laser sources, i.e. a 5 kW CO2- and a 4 kW Nd:YAG-laser, and of the main process parameters on the resulting weld quality will be investigated. One important aspect will concern the appearance of weld defects such as pores and hot cracks. The factors causing such internal imperfections will be analysed in order to find effective methods for preventing them. Weld microstructure and the associated corrosion and mechanical properties will be assessed with different techniques and adequate process parameters for high quality welds will be determined. The advantages and limitations of the applied welding processes will be evaluated for future applications.
In order to study damage in concrete exposed to fire, a series of continuous X-ray computed tomography (CT) measurements were performed on a concrete sample heated, in-situ, on one side. The water migration relative to time and 3D space and, in particular, the dynamic condensation and vaporization of water droplets in the pores was quantified. This approach shows significant potential for further investigation of fire-related concrete damage.
Water Migration in One-Side Heated Concrete: 4D In-Situ CT Monitoring of the Moisture-Clog-Effect
(2018)
In order to study damage in concrete exposed to fire, a series of continuous X-ray computed tomography (CT) measurements were performed on a concrete sample heated, in-situ, on one side. The water migration relative to time and 3D space and, in particular, the dynamic condensation and vaporization of water droplets in the pores was quantified. This approach shows significant potential for further investigation of fire-related concrete damage.
X-ray imaging techniques have an enormous potential to understand the microstructure, its evolution, and its link to mechanical, thermal, and transport properties. In this lecture we report the use of a powerful, yet not so wide-spread, set of X-ray techniques based on refraction effects. X-ray refraction allows determining the internal specific surface of materials (surface per unit volume) in a non-destructive fashion, position and orientation sensitive, and with a nanometric detectability. We demonstrate showcases of ceramics and composite materials, where microstructural parameters could be achieved in a way unrivalled even by high-resolution techniques such as electron microscopy or computed tomography. We present in situ analysis of the damage evolution during tensile load and the identification of void formation in parts produced by selective laser melting.
Non-destructive testing (NDT) of concrete structures plays an increasing role in civil engineering. This paper presents the results of systematic measurements carried out in the laboratory at BAM and on-site at several bridges using reconstructed and fused radar and ultrasonic echo data sets. For investigating the influence of concrete mixture, radar and ultrasonic measurements were performed at test specimens consisting of concrete mixtures with different pore content and distribution as well as with steel fibres. Further, it is demonstrated how the fusion of data sets recorded with different methods at the same structure (here: concrete bridges) enhances the information content in the fused data set. Different approaches for data fusion algorithms are discussed. The results of these investigations show the high potential of reconstruction and data fusion for the improvement and simplification of the interpretability of large data sets measured with impulse-echo methods. The presented results are based on the research project FOR384 funded by the DFG (Deutsche Forschungsgemeinschaft).