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Eingeladener Vortrag
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Bei der Bestimmung der Restlebensdauer zyklisch beanspruchter Bauteile kommt dem Schwellenwert für Ermüdungsrissausbreitung, K111, oft entscheidende Bedeutung zu. Dabei ist seine Anwendung weniger gesichert als bislang angenommen. Der Vortrag diskutiert Fragen der experimentellen Ermittlung des Schwellenwertes sowie seiner Anwendung auf Bauteile. Auf beiden Gebieten haben sich in den letzten Jahren Probleme ergeben, die bestehendes Wissen teilweise wieder in Frage stellen oder modifizieren. Im Beitrag diskutiert werden der Einfluss unterschiedlicher Rissschließmechanismen auf K111, Konsequenzen, die sich daraus hinsichtlich der Ermittlung und Übertragung des Kennwertes ergeben, sowie die Effekte von Einflussgrößen wie Spannungsverhältnis und Rissgröße, aber auch des Werkstoffgefüges und der damit korrelierten mechanischen Eigenschaften.
Recently three of the authors of this paper presented analytical solutions for reference loads of plate geometries with semi-elliptical surface cracks subjected to tension, bending, combined tension-bending and biaxial tension. These solutions were shown to provide more accurate crack driving force estimates than the conventional limit load solutions available in the literature, and the method behind them allowed for a wider application range. Within the present paper a methodology for the fracture analysis of thick-wall pressurized pipes using the R6 assessment method and considering both, biaxial and combined tension-bending loading is developed and validated. The analyses are carried out analytically, and the comparison between the predicted critical loads and experimental burst test failure loads shows satisfying agreement, this way demonstrating the potential of the proposed method.
ln den letzten Jahren hat sich gezeigt, dass die Ermittlung des Schwellenwertes DeltaKth nach den bestehenden Standardvorschriften für verschiedene Materialien zu nichtkonservativen Werten führt. Das ergibt sich im Vergleich mit Schwellenwerten, die man mit Anrissen erhält, die hinsichtlich der Ober- und der Unterlast komplett im Druckbereich erzeugt wurden. Dort, wo die Diskrepanz auftritt, verstärkt sie sich mit abnehmendem Spannungsverhältnis. ln der vorliegenden Studie wurden an einem mittel- und einem hochfesten Stahl bei unterschiedlichen Spannungsverhältnissen Schwellenwerte bestimmt. Anwendung fanden die konventionelle Lastabsenkungsmethode nach ASTM-Standard und ein Verfahren, bei dem der Langrissscbwellenwert als Endpunkt der sogenannten Zyklischen R-Kurve erhalten wird. Dieses folgt im Wesentlichen der von Pippan et al. entwickelten Methode, ergänzt diese jedoch durch eine eigene Verfahrensvariante.
In a number of previous papers, the authors have proposed a model for fracture mechanics based prediction of the S-N characteristics of metallic components with large microstructural defects. Here, an extension to materials that do not show large defects onto the fracture surfaces is provided. In such cases, an approach based on a so-called cyclic R-curve analysis is proposed for the determination of the initial flaw size, which has to be used in the calculation of fatigue crack propagation. The principle is explained and demonstrated by a first application to a welded joint.
The work aims at addressing the modelling and implementation of criteria for multiple crack propagation, including interaction and coalescence, for a more reliable fracture mechanics-based prediction of stress-life curves for weldments.
A large experimental work is presented in which micro-cracks have been made visible by heat-tinting at successive stages of fatigue life of the welded specimens. Here the correlation between the number of initiation sites and the applied stress level has been also investigated.
The criteria have been implemented in in-house software, which allows multiple fatigue crack propagation, and validated against selected experimental tests. The results have shown that the modelling of multiple crack propagation and interaction is crucial for the prediction of the fatigue strength of weldments, both in finite and infinite life regime.
The work aims at addressing the modelling and implementation of criteria for multiple crack propagation, including interaction and coalescence, for a more reliable fracture mechanics-based prediction of stress-life curves for weldments.
A large experimental work is presented in which micro-cracks have been made visible by heat-tinting at successive stages of fatigue life of the welded specimens. Here the correlation between the number of initiation sites and the applied stress level has been also investigated.
The criteria have been implemented in in-house software, which allows multiple fatigue crack propagation, and validated against selected experimental tests. The results have shown that the modelling of multiple crack propagation and interaction is crucial for the prediction of the fatigue strength of weldments, both in finite and infinite life regime.
Analytical flaw assessment
(2018)
The paper provides a review on analytical flaw assessment methods with the focus on fracture under monotonic loading and fatigue crack propagation. The first topic comprises linear elastic as well as elastic-plastic fracture mechanics approaches. It essentially follows their historical development. Topics which are separately discussed are reference/Limit loads, the treatment of secondary stresses, strength mismatch, constraint, unstable crack propagation (monotonic R-curve analyses) and statistical aspects. With respect to fatigue crack propagation the analytical treatment of crack closure and constraint and the Determination of the cyclic elastic-plastic crack driving force is discussed. Finally, cyclic Rcurve analyses are briefly addressed.
The paper provides an overview on the results of a German cluster project on the use of fracture mechanics to the determination of the fatigue strength of weldments with fatigue cracks originating at the weld toes. The approach includes (a) a concept for short crack propagation for which the common ΔK concept is not applicable and the crack closure effects are still being gradually build-up, (b) a method for determining fatigue life relevant initial crack sizes as they are needed in any fracture mechanics analysis and (c) multiple cracking and crack coalescence at load levels higher than the endurance limit. The analyses are stochastically performed. Both, the endurance limit and the finite life branch of the S-N curve are determined.
Besides a brief introduction into the approach, validation examples are presented. These comprise different weldment types (butt welds, cross joints and longitudinal stiffened plates), two steels (S355NL and S960QL) of quite different strengths, different weld geometries due to different welding techniques (WIG, MAG), as-welded and stress relieved welds and different stress ratios varying from R = -1 to R = 0.5.
As opposed to reviewing results on experimental determination of residual stress by diffraction, this paper discusses the open issues when dealing with residual stress determination in additive manufactured parts, in particular those manufactured with laser powder bed fusion techniques. Three points are addressed in detail: (a) the proper determination of the strain-free reference d0, (b) the problem of the determination of the principal axes, and (c) the use of the correct diffraction elastic constants. It is shown that all methods to determine the strain-free reference d0 suffer from caveats, and care must be taken in evaluating the most suitable for the problem being tackled. In addition, it is shown that, in some systems, the principal axes do correspond to the geometrical axes of the specimen, but this needs to be systematically checked, especially in the case of uni- or bidirectional hatching strategies. Finally, the need to experimentally determine the proper diffraction elastic constants is underlined, especially in the case of strongly textured specimens, which again depends on the deposition strategy.
The fatigue crack propagation threshold ΔKth is of paramount importance for any kind of damage tolerant design, but in contrast to this importance, the determination and application of the parameter is not on the firm ground as previously assumed. The paper discusses questions of its experimental determination as well as of its application to components. In both fields, new questions have been raised with the potential to challenge or modify long-standing knowledge. Against this background, the paper is an attempt to systematize the established knowledge as well as questions and open issues.