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Eingeladener Vortrag
- nein (433) (entfernen)
The common fatigue life certification of aircrafts according to the certification Standards 23 and 25 follows a building block approach. Static tests at room temperature as well in humid and high temperature conditions are done on the coupon level. Additionally, a full-scale static and fatigue test must be performed on the complete airframe (minimum on the fuselage together with the wing). For each type-certificate the complete building block approach test program must be performed.
Traditionally in Germany, the certification of sailplanes (Certification Standard 22) follows rather a family concept. A shared data base was created over the last 50 years based upon a large number of material testing. In addition to static tests at room temperature and hot-humid conditions, fatigue tests are also done on the coupon level. Additional static and fatigue tests were done on complex structures such as spar-beams, fuselages and full-scale wing structures. However, for each type-certificate, only static tests should be performed in full-scale. This concept is determined by the certification memorandum CM-S-006 “Composite Lightweight Aircraft” 2017.
The presentation was given as an introduction to the discussion about the future expectations and developments of the EASA concerning the type-certification of lightweight aircrafts according to CS22 at the OSTIVE Sailplane Development Panel Meeting at the EASA in Cologne on the 11th of October 2019.
Charakterisierung von Hochtemperaturwerkstoffen durch Zug- und Ermüdungsversuche an Kleinproben
(2019)
Die Verwendung von miniaturisierten Probengeometrien in der mechanischen Prüfung ermöglicht die Entnahme des Probenmaterials direkt aus kritischen Bereichen wie Fügeverbindungen und ermöglicht die Prüfung von kleinen Bauteilen wie additiv gefertigten Strukturen. In der vorliegenden Arbeit werden exemplarisch die Ergebnisse von vergleichenden Zug- und niederzyklischen Schwingversuchen (LCF) an dem austenitischen Stahl AISI 316L und der Nickelbasislegierung IN718 vorgestellt. Die Prüfergebnisse der Kleinproben aus AISI 316L weisen die charakteristischen Eigenschaften des Werkstoffs auf, und die Analyse der Zug- und Ermüdungsdaten führt zu Werten, die den Literaturdaten weitgehend entsprechen. Der direkte Vergleich mit Standardprobendaten zeigt jedoch systematische Abweichungen bei Zugfestigkeit, Dehngrenze und Gleichmaßdehnung, die in diesem Beitrag diskutiert werden.
The application of implants e.g. for osteosynthesis or substitution of worn out joints is common practice since decades. Successes in surgery and orthopedics are highly dependent on the use of artificial parts for implanting into the human body. Over the years the number of surgical procedures and the number of different implants were growing rapidly. Implants, however, are exposed to complex mechanical, corrosive and tribological loads along with restriction in geometric dimension. While being essentially successful, the sheer number of cases leads to a rising number of implant failures. Such failures are painful for the affected patients and are very costly.
The failure cases presented in this paper occurred from 1981 to 2016. The predominant failure mechanism of all kinds of implants is fatigue fracture. Fatigue cracks are initiated due to a whole bunch of reasons: Material defects and fabrication defects are rare events. The main factors are cyclic overload due to improper fitting with delayed bone healing, corrosion and unauthorized modification of the implant during surgery
Der Fachbereich Mechanik der Polymerwerkstoffe befasst sich mit der Charakterisierung der mechanischen Eigenschaften und der Degradation von Polymeren und Faserverbundwerkstoffen, die in hochbeanspruchten, sicherheitsrelevanten Konstruktionen wie jenen des Flugzeugbaus, des Automobilbaus und der Windenergie-Industrie eingesetzt werden. Auch die Analyse der chemischen und physikalischen Eigenschaften von Polymeren zählt zu unserem Aufgabenbereich.
Das Spektrum reicht von der statischen Festigkeit über die Betriebsfestigkeit, die Messung bruchmechanischer und viskoelastischer Parameter bis hin zur Formulierung molekularer Schädigungsmechanismen.
Statistically the mean time between damage events on rotor blades is 6 years (Deutscher Windenergie Report 2006). Due to imperfection in the production the shell structures get cracks after a few years fare before the designed life time. A shell test rig was built at BAM for efficient research on the effects of defects in production.
In-situ and ex-situ NDT give a better understanding from degradation processes in composite materials.
With advanced methods in the research on the fatigue behaviour of FRP it was found a load level of infinite life for GFRP and CFRP. This is in the range of typical strain values of airliners and rotor blades in normal operation.
Due to the fibre-composite nature NDT techniques have to be suitable to a wide length scale to image micro cracking as well as bigger defects. Therefore different techniques have to be applied and developed.
Even for the basic measurements of material data for design and engineering of composite structures there is a need to upgrade standards. With a new shear frame test rig more precise values can be obtained.
With advanced methods in the research on the fatigue behaviour of FRP it was found a load level of infinite life for GFRP and CFRP. This is in the range of typical strain values of airliners and rotor blades in normal operation.
Statistically the mean time between damage events on rotor blades is 6 years (Deutscher Windenergie Report 2006). Due to imperfection in the production the shell structures get cracks after a few years fare before the designed life time. A shell test rig was built at BAM for efficient research on the effects of defects in production.
Test blades of ~10m are an efficient way for SHM research and evaluation of NDT-methods and blade geometry.
A shell test bench was developed at BAM 5.3 which allows for static and fatigue testing of curved fiber-reinforced plastic (FRP) structures, during which in-situ the damage state can be non-destructively inspected by thermography and strain-field measurement techniques. Sandwich shell specimens with typical wind turbine blade manufacturing defects were designed and tested. The tested imperfections show a fairly significant reduction (up to 90%) of the shell test specimens‘ lifetime, depending on the type of imperfection. Using the in-situ NDT methods incorporated in the shell test bench, the location and cycle time of the initial defects and the damage evolution was investigated.
Cyclic mechanical performance and microstructure evolution of P92 under LCF and TMF conditions
(2019)
9-12% Cr ferritic-martensitic stainless steels are widely used as high temperature construction materials in fossil fueled power plants due to their excellent creep and oxidation resistance, but changes in electricity markets during the last two decades have considerably changed the typical working conditions of these facilities. The growing contribution of renewable energy sources in power generation forces most of these plants into flexible operation with frequent load shifts or shutdowns. These cyclic operation profiles constitute a major lifetime issue, raising the question which fundamental processes govern the reaction of ferritic-martensitic steels to cyclic load and temperature variations.
The present contribution reports on current findings obtained in a multidisciplinary project funded by German Ministry of Education and Research (BMBF) which combines cyclic mechanical and cyclic oxidation testing of different 9-12% Cr grades with detailed microstructural analyses and related micromechanical modeling.
In this contribution, an overview will be given on the results obtained in the mechanical testing programme of the project. Mechanical analyses were carried out on P91 and (mainly) P92 steel grades, particularly looking at softening phenomena and lifetimes obtained in isothermal cyclic loading (low cycle fatigue, LCF), non-isothermal cyclic loading (thermo-mechanical fatigue, TMF), and service-like combinations of fatigue and creep/relaxation periods. For this purpose, cylindrical specimens were extracted from thick-walled steam pipes, orthogonal to the pipe axis, and subjected to strain controlled cyclic loading (± 0.2 to ±0.5 % mechanical strain). Temperature intervals of TMF tests were chosen as either 300-620°C or 500-620°C, resembling so-called warm or hot start conditions of a power plant.
The test results will be presented and discussed with a focus on the impact of hold periods during testing (combined creep/relaxation-fatigue conditions) on mechanical softening, lifetime and formation of cracks. The findings will be complemented by results on the modification of the hierarchical ferritic-martensitic microstructure under different loading scenarios.
9-12% Cr ferritic-martensitic stainless steels are widely used as high temperature construction materials in fossil fueled power plants due to their excellent creep and oxidation resistance, but changes in electricity markets during the last two decades have considerably changed the typical working conditions of these facilities. The growing share of renewable energy sources in power generation forces most of these plants into flexible operation with frequent load shifts or shutdowns. These cyclic operation profiles constitute a major lifetime issue, raising the question which fundamental processes govern the reaction of ferritic-martensitic steels to cyclic load and temperature variations.
The present contribution reports on current findings obtained in a multidisciplinary project funded by German Ministry of Education and Research (BMBF) which combines cyclic mechanical and cyclic oxidation testing of different 9-12% Cr grades with detailed microstructural analyses and related micromechanical modeling.
In the present first part of our contribution, an overview will be given on the results obtained in the mechanical testing programme of the project. Mechanical analyses were carried out on P91 and (mainly) P92 steel grades, particularly looking at softening phenomena and lifetimes obtained in isothermal cyclic loading (low cycle fatigue, LCF), non-isothermal cyclic loading (thermo-mechanical fatigue, TMF), and service-like combinations of creep and fatigue periods. For this purpose, cylindrical specimens were extracted from thick-walled steam pipes, orthogonal to the pipe axis, and subjected to strain controlled cyclic loading (± 0.2 to ±0.5 % mechanical strain) to different degrees of softening at temperatures up to 620 °C.
The test results will be presented and discussed with a focus on the impact of hold periods (i.e. combined creep-fatigue conditions) on mechanical softening, lifetime and crack formation. Details on the microstructural evolution and their representation in a micromechanical model will be given in a second, complementary contribution to this conference.
Extensometer sind seit Jahrzehnten im Einsatz und bilden die Basis für eine präzise Dehnungsmessung in werkstoffmechanischen Versuchen. Jedoch ist die Temperaturstabilität von Extensometern häufig noch nicht ausreichend beachtet worden, um Fehler verursacht durch Temperaturschwankungen zu minimieren. Dieses wird derzeit nicht nur in Deutschland, sondern auch international zunehmend diskutiert. Datenblätter von Extensometern sind teils unvollständig besonders hinsichtlich von Temperatureinflüssen. Extensometer für den Einsatz bei höheren Temperaturen sollen z.B. laut Normen für dehnungsgeregelte Ermüdungsversuche mit Luft oder Wasser aktiv gekühlt werden. Jedoch schreiben die Normen keine Temperatur-Toleranzen für Extensometer vor. Dehnungsfehler verursacht durch Temperaturschwankungen am Extensometer bleiben meist verborgen, da die Temperatur des Extensometers standardmäßig gar nicht gemessen wird. Die Ursache von Einflüssen zur Temperaturstabilität von Extensometern wird erläutert. Ein einfaches Rechenbeispiel zeigt die Empfindlichkeit von Extensometern gegenüber Temperaturschwankungen und die Auswirkungen auf den Dehnungsfehler. Lösungsmöglichkeiten zur Optimierung werden aufgezeigt. Der Anwender von Extensometern soll sensibilisiert werden, um der Temperaturstabilität von Extensometern sowohl hinsichtlich Herstellerspezifikationen als auch bei der Anwendung von Extensometern im Prüflabor mehr Aufmerksamkeit zu schenken, um letztlich die Qualität von Versuchsergebnissen zu verbessern. Empfehlungen an Extensometerhersteller werden formuliert. Dieses Thema wird zukünftig auch in Prüfnormen mehr Aufmerksamkeit geschenkt werden. Es werden Maßnahmen zur Verbesserung der Temperaturstabilität von Extensometern Einzug in Prüfnomen finden, um letztlich verlässlichere Versuchsergebnisse zu erhalten. Es ist beabsichtigt, eine Verbesserung der Temperaturstabilität von Extensometern z.B. bei der nächsten Revision der Prüfnormen ISO 12106 und ISO 12111 für dehnungsgeregelte LCF- und TMF-Versuche zu berücksichtigen.